2006 YAMAHA MAJESTY 180 check engine

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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Use caution when adding electri-
cal accessories. If electrical
accessories exceed the capacity
of the scooter’s electrical system
an electric failure could result,
which could cause a dangerous
loss of lights or engine power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off
when refueling.
• Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
scooter in an area that has ade-
quate ventilation.
Always turn the engine off before
leaving the scooter unattended
and remove the key from the
main switch. When parking the
scooter, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,
park the scooter in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the scooter on a
slope or soft ground, otherwise
it may fall over.
• Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
EAU10360
Further safe-riding points
Be sure to signal clearly when
making turns.
Braking can be extremely difficult
on a wet road. Avoid hard bra-
king, because the scooter could
slide. Apply the brakes slowly
when stopping on a wet surface.
Slow down as you approach a
corner or turn. Once you have
completed a turn, accelerate
slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely slip-
pery when wet. Slow down and
cross them with caution. Keep
the scooter upright, otherwise it
could slide out from under you.
The brake lining could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
1
tSAFETY INFORMATION
1-4
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EAU11030
Turn signal indicator lights “c” and
“
d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11390
Oil change indicator light “z”
1. Oil change indicator
2. Coolant temperature warning light
This indicator light comes on at the
initial 1000 km (600 mi) and every
3000 km (1800 mi) thereafter to indi-cate that the engine oil should be
changed.
If the engine oil is changed before the
oil change indicator comes on (i.e.
before the periodic oil change interval
has been reached), the indicator light
must be reset after the oil change for
the next periodic oil change to be
indicated at the correct time. (See
page 6-8.)
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Set the engine stop switch to “h”
and turn the key to “ON”.
2. Check that the indicator comes
on for a few seconds and then
goes off.
3. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
NOTE:
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
EAUM1080
Coolant temperature warning light
“
y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Turn the key to “h”.
2. If the warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
12
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
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EAU15603
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-3, 3-6
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-7
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-9
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-10
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 3-5, 6-15
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 3-6, 6-15
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
5-2, 6-12
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
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EAU16760
Starting off
1. Passenger handle
NOTE:
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the centers-
tand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and
deceleration
The speed can be adjusted by ope-
ning and closing the throttle. To incre-
ase the speed, turn the throttle grip in
direction (a). To reduce the speed,
turn the throttle grip in direction (b).
EAU16791
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
EWA10300
s s
WARNING
Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the sco-
oter may skid or overturn.
Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers beco-
me extremely slippery when wet.
Therefore, slow down when
approaching such areas and
cross them with caution.
1
5
OPERATION AND IMPORTANT RIDING POINTS
5-2
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Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as bra-
king downhill can be very diffi-
cult.
EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not put
an excessive load on it for the first 1000
km (600 mi). The various parts in the engi-
ne wear and polish themselves to the
correct operating clearances. During this
period, prolonged full-throttle operation
or any condition that might result in engi-
ne overheating must be avoided.
EAU17150
0~150 km (0~90 mi)
Avoid prolonged operation above 1/3
throttle.
After every hour of operation, stop the
engine, and then let it cool for five to
ten minutes.Vary the engine speed from time to
time. Do not operate the engine at
one set throttle position.
150~500 km (90~300 mi)
Avoid prolonged operation above 1/2
throttle.
Rev the engine freely through the
gears, but do not use full throttle at
any time.
500~1000 km (300~600 mi)
Avoid prolonged operation above 3/4
throttle.
ECA10370
CAUTION
After 1000 km (600 mi) of operation,
the transmission oil must be chan-
ged.
1000 km (600 mi) and beyond
Avoid prolonged full-throttle opera-
tion. Vary the engine speed occasio-
nally.
ECA10270
CAUTION
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17200
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
s s
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn.5
OPERATION AND IMPORTANT RIDING POINTS
5-3
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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
6-3
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
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
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