2003 YAMAHA MAJESTY 250 air filter

2-1
EAU00026
DESCRIPTIONPart locations
2
1. Rear storage compartment (page 3-20)
2. Grab bar (page 5-2)
3. Shock absorber spring preload
adjusting ring (page 3-21)
4. Air filter element (page 6-21)5. V-belt case air filter element (page 6-22)
6. Centerstand (page 6-31)
7. Sidestand (page 3-22, 6-31)
8. Fuel tank cap (page 3-15)
12
3
4 5 6 7
8
Left view
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PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ....................................................6-1
Periodic maintenance and lubrication chart .........6-3
Removing and installing the cowlings and
panel .................................................................6-6
Checking the spark plug ....................................6-12
Engine oil ...........................................................6-14
Final transmission oil .........................................6-18
Coolant ..............................................................6-19
Air filter and V-belt case air filter elements ........6-21
Air flow louver ....................................................6-23
Adjusting the throttle cable free play .................6-23
Adjusting the valve clearance ...........................6-23
Tires ...................................................................6-24
Cast wheels .......................................................6-26
Adjusting the front and rear brake lever
free play ..........................................................6-27
Checking the front and rear brake pads ............6-28
Checking the brake fluid level ............................6-29
Changing the brake fluid ....................................6-30
Checking and lubricating the cables ..................6-30
Checking and lubricating the throttle grip
and cable ........................................................6-31
Lubricating the front and rear brake levers ........6-31Checking and lubricating the centerstand
and sidestand .................................................6-31
Checking the front fork ......................................6-32
Checking the steering ........................................6-33
Checking the wheel bearings ............................6-33
Removing the battery cover ...............................6-34
Battery ...............................................................6-34
Replacing the fuses ...........................................6-36
Replacing a headlight bulb ................................6-37
Replacing a front turn signal light bulb ..............6-39
Replacing a rear turn signal light bulb ...............6-40
Replacing a tail/brake light bulb .........................6-40
Replacing the license plate light bulb ................6-41
Troubleshooting .................................................6-42
Troubleshooting charts ......................................6-43
6
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6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00464
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.
EAU03623
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.)
EW000060
w
If you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
EAU00466
w
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
EAU03685
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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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
20*Engine oil strainer•Clean.√
21
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
22 Final transmission oil•Check vehicle for oil leakage.√√ √
•Change.√√√
23
*V-belt•Replace.Every 20,000 km
24
*Front and rear brake
switches•Check operation.√√√√√ √
25 Moving parts and cables•Lubricate.√√√√ √
26
*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
27
*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03627
Air filter and V-belt case air
filter elements
Air filter and V-belt case air filter elements, cleaningThe air filter and V-belt case air filter
elements should be cleaned at the
intervals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
quently if you are riding in unusually
wet or dusty areas.
EC000092
cC
8
8
Make sure that each filter ele-
ment is properly seated in its
case.
8 8
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston and/or cylinder may
become excessively worn.
4. Check the sponge material for
damage and replace it if neces-
sary.
5. Allow the sponge material to dry.
6. Apply oil of the recommended
type to the entire surface of the
sponge material, and then
squeeze the excess oil out.
Cleaning the air filter element
1. Place the scooter on the center-
stand.
2. Remove the air filter case cover
by removing the screws.
3. Pull the sponge material out
along with the mesh sheet, clean
it with solvent, and then squeeze
the remaining solvent out.
1
2 2
34
1. Air filter case cover
2. Screw (×5)
3. Sponge material
4. Mesh sheet
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
The sponge material should be wet
but not dripping.
7. Insert the sponge material into
the air filter case.
8. Install the air filter case cover by
installing the screws.
4. Blow the dirt out of the air filter
element with compressed air as
shown.
5. Check the V-belt case air filter
element for damage and replace
it if necessary.
6. Install the V-belt case air filter
element cover by installing the
screws.
7. Install the air filter case cover by
installing the screws.
8. Install the cowling.
21
1. V-belt case air filter cover
2. V-belt case air filter element
Cleaning the V-belt case air filter
element
1. Remove cowling A. (See page
6-7 for cowling removal and
installation procedures.)
2. Remove the air filter case cover
by removing the screws.
3. Remove the V-belt case air filter
cover by removing the screws.
21
1. V-belt case air filter cover
2. Screw (×3)
Recommended oil:
Engine oil
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8-2
SPECIFICATIONS
8
Final transmission oil
Type Engine oil SAE 10W-30
(API SE)
Total amount 0.25 L
Radiator capacity
(including all routes)1.4 L
Air filterWet type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 12 L
Carburetor
Manufacturer TEIKEI
Model × quantity Y28V-1E × 1
Spark plug
Manufacturer/model NGK/DR8EA
Spark plug gap 0.6–0.7 mm
Clutch typeDry, centrifugal automatic
Transmission
Primary reduction system Helical gear
Primary reduction ratio 40/15 (2.666)
Secondary reduction system Helical gear
Secondary reduction ratio 38/15 (2.533)Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Caster angle 28°
Trail 103 mm
Tires
Front
Type Tubeless
Size 110/90-12 64L
Manufacturer/ IRC/MB67
model MICHELIN/BOPPER
Rear
Type Tubeless
Size 130/70-12 62L
Manufacturer/ IRC/MB67
model MICHELIN/BOPPER
Maximum load* 178 kg
Air pressure (cold tire)
up to 90 kg load*
Front175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear 200 kPa (2.00 kgf/cm
2, 2.00 bar)
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