2003 YAMAHA MAJESTY 250 air condition

4-1
EAU01114
PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
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Pre-operation check listPre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-5, 3-16– 3-17
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-14–6-17
Final transmission oil•Check vehicle for oil leakage. 6-18–6-19
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.3-5, 6-19–6-20
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-11, 6-27–6-30
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4-2
PRE-OPERATION CHECKS
4
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-12, 6-27–6-30
Throttle grip•Make sure that operation is smooth.
•Check cable free play.
•If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-23, 6-31
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-24–6-27
Brake levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.3-11–3-12, 6-27, 6-31
Centerstand, sidestand•Make sure that operation is smooth.
•Lubricate pivots if necessary.6-31–6-32
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.3-2–3-11, 6-37–6-42
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-22–3-23 ITEM CHECKS PAGE
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6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
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Owner’s tool kitTool kitThe owner’s tool kit is located inside
the rear storage compartment. (See
page 3-20 for the rear storage com-
partment opening procedures.)
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If you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
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This scooter is designed for use
on paved roads only. If this scoot-
er is operated in abnormally dusty,
muddy or wet conditions, the air
filter element should be cleaned or
replaced more frequently, other-
wise rapid engine wear may result.
Consult a Yamaha dealer for prop-
er maintenance intervals.
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Periodic maintenance and lubrication chartPeriodic maintenance and lubrication chartNOTE:
8 8
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2 Spark plug•Check condition.
•Clean and regap.√√
•Replace.√√
3
*Valves•Check valve clearance.
•Adjust.√√
4 Air filter element•Clean.√√
•Replace.√√
5V-belt case air filter
element•Clean.√√√√
6
*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7
*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To install the panel
Place the panel in the original posi-
tion, and then install the bolts.
1
1
1. Tab (×4)
To remove the spark plug
1. Remove cowling B. (See page
6-8 for cowling removal and
installation procedures.)
2. Remove the spark plug cap.
1
1. Spark plug cap
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Checking the spark plugSpark plug, checkingThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your scooter, you should
keep the following precautions in
mind.
8 8
NEVER OVERLOAD THE
SCOOTER! Operation of an
overloaded scooter may result
in tire damage, loss of control,
or severe injury. Make sure
that the total weight of rider,
cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.
8 8
Do not carry along loosely
packed items, which can shift
during a ride.
8 8
Securely pack the heaviest
items close to the center of the
scooter and distribute the
weight evenly on both sides.Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or
if the sidewall is cracked, have a
Yamaha dealer replace the tire imme-
diately.
1a
1. Sidewall
a. Tire tread depth
8 8
Adjust the suspension and tire
air pressure with regard to the
load.
8 8
Check the tire condition and
air pressure before each ride.
Minimum tire tread depth
(front and rear)1.6 mm
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6 8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boiling
point of the fluid and may result
in vapor lock, and dirt may clog
the ABS hydraulic unit valves.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
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Checking and lubricating the
cables
Cables, checking and lubricatingThe operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends
should be lubricated if necessary. If
a cable is damaged or does not move
smoothly, have a Yamaha dealer
check or replace it.
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Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
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Changing the brake fluidBrake fluid, changingHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hoses: Replace every four
years.Recommended lubricant:
Engine oil
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6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6
To check the operation
1. Place the scooter on a level sur-
face and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
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cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
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Checking the front forkFront fork, checkingThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
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Securely support the scooter so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
Centerstand
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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