2005 YAMAHA MAJESTY 125 maintenance

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and Instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTION..........................................3-1
Main switch.......................................3-1
Indicator lights ..................................3-1
Speedometer unit .............................3-3
Battery voltage/fuel gauge ...............3-3
Clock .................................................3-4
Handlebar switches ..........................3-4
Front brake lever...............................3-5
Rear brake lever................................3-6
Fuel tank cap ....................................3-6
Fuel ...................................................3-6
Seat...................................................3-7
Front storage compartment..............3-7
Storage compartment.......................3-7
Adjusting the rear shock absorber
assemblies.....................................3-8
Sidestand ..........................................3-8
Sidestand switch operation check ...3-9
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-2
Acceleration and deceleration ..........5-2
Braking..............................................5-2
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR REPAIRS................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-6
Engine oil ..........................................6-7
Final gear oil .....................................6-9
Coolant ...........................................6-10
Air filter and V-belt case air filter
elements ......................................6-11
Adjusting the carburetor .................6-12
Checking the throttle cable free
play ..............................................6-12
Tires ................................................6-13
Adjusting the brake lever free
play ..............................................6-15
Checking the front and rear brake
pads.............................................6-15
Checking the brake fluid level ........6-15
Changing the brake fluid ................6-16Checking and lubricating the
cables ..........................................6-16
Checking and lubricating the
centerstand and sidestand .........6-17
Checking the front fork ...................6-17
Checking the steering.....................6-17
Checking the wheel bearings .........6-18
Battery ............................................6-18
Replacing the fuse ..........................6-20
Replacing the headlight bulb or
a front turn signal light bulb ........6-20
Replacing a front turn signal light
bulb .............................................6-21
Replacing the license plate light
bulb .............................................6-21
Replacing the tail/brake light bulb
or a rear turn signal light bulb .....6-22
Troubleshooting ..............................6-23
Troubleshooting chart .....................6-24
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage .............................................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ......................9-1
TABLE OF CONTENTS
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EAU10260
SCOOTERS ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE
EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS SCOOTER.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
SCOOTER OPERATION.
OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S
MANUAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.Safe riding
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This scooter is designed to carry
the operator and passenger.
The failure of motorists to detect
and recognize scooters in traffic
is the predominating cause of
automobile/scooter accidents.
Many accidents have been cau-
sed by an automobile driver who
did not see the scooter. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when appro-
aching and passing through
intersections, since intersec-
tions are the most likely places
for scooter accidents to occur.
• Ride where other motorists can
see you. Avoid riding in anot-
her motorist’s blind spot.
Many accidents involve inexpe-
rienced operators. In fact, many
operators who have been invol-
ved in accidents do not even
have a current driver’s license.
• Make sure that you are quali-
fied and that you only lend your
scooter to other qualified ope-
rators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your scooter where
there is no traffic until you have
become thoroughly familiar
with the scooter and all of its
controls.
Many accidents have been cau-
sed by error of the scooter ope-
rator. A typical error made by the
operator is veering wide on a turn
due to EXCESSIVE SPEED or
undercornering (insufficient lean
angle for the speed).
SAFETY INFORMATION t
1-1
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EAU17280
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 follo-
wing 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, GEO-
GRAPHICAL LOCATION, AND INDIVI-
DUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
s s
WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EWA10330
s s
WARNING
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air fil-
ter element should be cleaned or
replaced more frequently, otherwi-
se rapid engine wear may result.
Consult a Yamaha dealer for proper
maintenance intervals.
EAU17320
Owner’s tool kit
1. Owner’s tool kit
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended toassist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
NOTE:
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
EWA10350
s s
WARNING
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any chan-
ges.
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
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Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
1 * Fuel line • Check fuel and vacuum hoses for cracks or damage.√√√√ √
2 * Fuel filter • Check condition.√√
3 Spark plug • Check condition.
• Clean and regap.√√
• Replace.√√
4 * Valves •Check valve clearance.
• Adjust.√√
5 Air filter element • Clean.√√
• Replace.√√
6 V-belt case air filter • Clean.√√√√
element
7 * Battery • Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.√√√√ √
8 * Front brake • Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √
• Replace brake pads. Whenever worn to the limit
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ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
9 * Rear brake • Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √
•Replace brake pads. Whenever worn to the limit
10 * Wheels • Check runout and for damage.√√√√
11 * Wheel bearings • Check bearing for looseness or damage.√√√√
12 * Steering bearings • Check bearing play and steering for roughness.√√ √ √√
• Lubricate with lithium-soap-based grease. Every 24000 km
13 * Chassis fasteners • Make sure that all nuts, bolts and screws are √√√√ √
properly tightened.
14 Sidestand, centerstand • Check operation.
• Lubricate.√√√√ √
15 * Sidestand switch • Check operation.√√ √ √√ √
16 * Front fork • Check operation and for oil leakage.√√√√
17 * Shock absorber • Check operation and shock absorbers for oil leakage.√√√√
assemblies
18 * Carburetor • Adjust engine idling speed.√√ √ √√ √
19 Engine oil • Change. (See page *-*.)√When the oil change
indicator light comes on (every 3000 km)
• Check oil level and vehicle for oil leakage. Every 3000 km√
20 * Engine oil strainer • Clean.√
21 * Cooling system • Check coolant level and vehicle for coolant leakage.√√√√ √
• Change. Every 3 years
22 Final gear oil • Check oil level and vehicle for oil leakage.√√ √
• Change.√√√
23 * V-belt • Replace. Every 10000 km
PERIODIC MAINTENANCE AND MINOR REPAIR
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ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
24 * Front and rear brake • Check operation.√√ √ √√ √
switches
25 Moving parts and cables • Lubricate.√√√√ √
26 * Muffler and exhaust pipe • Check the screw clamp for looseness.√√ √ √√
27 * Lights, signals and • Check operation.
switches • Adjust headlight beam.√√ √ √√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
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6
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EAU18711
Removing and installing
cowlings and panels
Cowling A
1. Cowling
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
EAU18790
Cowling B
1. Panel
2. Screw (x1)
To remove the cowling
Remove the screws, and then take
the cowling off.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAU19210
Panels
1. Panel
2. Screw (x4)
To remove the panel
Remove the screws, and then take
the panel off.
T
o install the panel
Place the panel in the original posi-
tion, and then install the screws.
321
1
2
1
6
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EAU19620
Checking the spark plug
1. Spark plug cap
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it 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.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is riddennormally). If the spark plug shows a
distinctly different color, the engine
could be defective. Do not attempt to
diagnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.
1. Spark plug wrench
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
1. Spark plug gap
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4~1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
Tightening torque:
Spark plug:
20 Nm 2,0 m•kgf, 14,46ft•lb)
Spark plug gap:
0,7~0,8 mm (0,0275in-0,0315in)
Specified spark plug:
CR8E (NGK)
6
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