2003 YAMAHA MAJESTY 250 coolant

2-2
DESCRIPTION
2
9. Passenger seat
10. Rider seat (page 3-18)
11. Air flow louver (page 6-23)
12. Headlight (page 6-37)
13. Radiator 14. Battery (page 6-34)
15. Fuse box (page 6-36)
16. Coolant reservoir cap (page 6-20)
17. Coolant level check window (page 6-19)
18. Engine oil filler cap (page 6-15)11
12
13 16 17
18
14 15
109Right view
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2-3
DESCRIPTION
2
1
23
46578910
11
12 13
Controls and instruments
1. Rear brake lever (page 3-12)
2. Left handlebar switches (page 3-10)
3. Front storage compartment A (page 3-19)
4. Coolant temperature gauge (page 3-5)
5. Tachometer (page 3-4)
6. Speedometer (page 3-4)
7. Multi-function display (page 3-5)8. Fuel gauge (page 3-5)
9. Right handlebar switches (page 3-11)
10. Front brake lever (page 3-11)
11. Throttle grip (page 6-23, 6-31)
12. Front storage compartment B (page 3-20)
13. Main switch/steering lock (page 3-1)
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INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ...................................................................3-1
Indicator and warning lights ...............................................................3-2
Speedometer .....................................................................................3-4
Tachometer .......................................................................................3-4
Fuel gauge .........................................................................................3-5
Coolant temperature gauge ...............................................................3-5
Multi-function display .........................................................................3-5
Anti-theft alarm (optional) ................................................................3-10
Handlebar switches .........................................................................3-10
Front brake lever .............................................................................3-11
Rear brake lever ..............................................................................3-12
ABS .................................................................................................3-13
Fuel tank cap ...................................................................................3-15
Fuel ..................................................................................................3-16
Catalytic converter ...........................................................................3-17
Rider seat ........................................................................................3-18
Adjusting the rider seat ....................................................................3-18
Storage compartments ....................................................................3-19
Adjusting the shock absorber assemblies .......................................3-21
Sidestand .........................................................................................3-22
Ignition circuit cut-off system ...........................................................3-22
3
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EAU00110
Fuel gaugeFuel gaugeThe fuel gauge indicates the amount
of fuel in the fuel tank. The needle
moves towards “E” (Empty) as the
fuel level decreases. When the nee-
dle reaches “E”, approximately 2 L of
fuel remain in the fuel tank. If this
occurs, refuel as soon as possible.
NOTE:
Do not allow the fuel tank to empty
itself completely.
INSTRUMENT AND CONTROL FUNCTIONS
3
1
1. Fuel gauge
EAU03124
Coolant temperature gaugeCoolant temperature gaugeThis gauge indicates the coolant tem-
perature when the main switch is on.
The engine operating temperature
will vary with changes in weather and
engine load. If the needle points to
the red mark, stop your scooter and
let the engine cool. (See page 6-44
for details.)
EC000002
cC
Do not operate the engine if it is
overheated.
1
2
1. Coolant temperature gauge
2. Red mark
EAU04906
Multi-function displayDisplay, multi-functionThe multi-function display is
equipped with the following:
8a tripmeter (which shows the dis-
tance traveled since it was last
set to zero)
8a fuel tripmeter (which shows the
distance traveled when the fuel
level reaches approximately
2.0 L)
8an odometer (which shows the
total distance traveled)
8a clock
8an outside temperature display
1
2
3
1. Tripmeter
2. Odometer, fuel tripmeter
3. Clock, outside temperature and voltage
display
3-5
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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.
EAU03439
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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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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6-5
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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6-19
PERIODIC MAINTENANCE AND MINOR REPAIR
67. Check the final transmission
case for oil leakage. If oil is leak-
ing, check for the cause.
2. Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.
1
2
1. Maximum level mark
2. Minimum level mark
EAU04591
CoolantCoolantThe coolant reservoir is located
under the battery cover. (See page
6-34 for battery cover removal and
installation procedures.)
To check the coolant level
1. Place the scooter on a level sur-
face and hold it in an upright
position.
NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the scooter is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
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