2008 YAMAHA MAJESTY 125 maintenance

INTRODUCTION
IMPORTANT MANUAL INFORMATION
TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Further safe-riding points .................1-4
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator lights ..................................3-2
Speedometer unit .............................3-2
Battery voltage/fuel gauge ...............3-3
Clock .................................................3-4
Anti-theft alarm (optional) .................3-5
Handlebar switches ..........................3-5
Front brake lever...............................3-6
Rear brake lever................................3-6
Fuel tank cap ....................................3-7
Fuel ...................................................3-8
Fuel tank breather/overflow hose .....3-9
Catalytic converter............................3-9
Seat...................................................3-9
Front storage compartment............3-10Storage compartment.....................3-11
Adjusting the shock absorber
assemblies...................................3-12
Sidestand ........................................3-12
Ignition circuit cut-off system .........3-13
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-2
Acceleration and deceleration ..........5-2
Braking..............................................5-2
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-3
Removing and installing panels........6-6
Checking the spark plug ..................6-7
Engine oil ..........................................6-9
Final transmission oil ......................6-11
Coolant ...........................................6-12
Air filter and V-belt case air filter
elements ......................................6-14Adjusting the carburetor .................6-15
Adjusting the throttle cable free
play ..............................................6-15
Valve clearance ...............................6-16
Tires ................................................6-16
Cast wheels ....................................6-18
Front and rear brake lever free
play ..............................................6-19
Checking the front and rear brake
pads.............................................6-19
Checking the brake fluid level ........6-20
Changing the brake fluid ................6-21
Checking and lubricating
the cables ....................................6-21
Lubricating the front and rear brake
levers ...........................................6-22
Checking and lubricating the
centerstand and sidestand .........6-22
Checking the front fork ...................6-23
Checking the steering.....................6-23
Checking the wheel bearings .........6-24
Battery ............................................6-24
Replacing the fuses ........................6-26
Replacing a headlight bulb .............6-27
Replacing a front turn signal
light bulb......................................6-29
Replacing the tail/brake light bulb
or a rear turn signal light bulb .....6-30
Replacing the license plate light
bulb .............................................6-31
Replacing the auxiliary light bulb ...6-31
TABLE OF CONTENTS
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EAU10261
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).
• Always obey the speed limit
and never travel faster than
warranted by road and traffic
conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
1
tSAFETY INFORMATION
1-1
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EAU13220
Fuel
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel
in the tank. When refueling, be sure to
insert the pump nozzle into the fuel
tank filler hole and to fill the tank to
the bottom of the filler tube as shown.
EWA10880
s s
WARNING
Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
Avoid spilling fuel on the hot
engine.
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfa-
ces or plastic parts.
EAU33520
ECA11400
CAUTION:
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem.
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
10.5 L ( 2.77US gal) (2.31 Imp.gal)
Fuel reserve amount
3 L (0.79 US gal) (0.66 Imp gal)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-8
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EAUB1300
Fuel tank breather/overflow
hose
Before operating the motorcycle:
Check the fuel tank
breather/overflow hose connec-
tion.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
1. Fuel tank breather/overflow hose
EAU13431
Catalytic converter
This model is equipped with a cataly-
tic converter in the exhaust system.
EWA10860
s s
WARNING
The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
ECA10700
CAUTION:
The following precautions must be
observed to prevent a fire hazard or
other damages.
Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
Never park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Do not allow the engine to idle
too long.
EAU13891
Seat
To open the seat
1. Open
1. Insert the key in the lock, and
then turn it as shown.
1. Rider seat
2. Fold the seat up.
1
1
1
3
INSTRUMENT AND CONTROL FUNCTIONS
3-9
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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.
EAU17450
Owner’s tool kit
1. Owner's tool kit
The owner’s tool kit is located inside the
storage compartment. (See page 3-11.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist 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.
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
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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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
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EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
ODOMETER READING (x 1000 Km)
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
1*Fuel line• Check fuel and vacuum hoses for cracks or damage.√√√√ √
• Check condition.
2Spark plug• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√√√
4Air filter element• Clean.√√• Replace.√√
5V-belt case air filter
• Clean.√√√√
element
6*Battery• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.√√√√ √
7*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
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24CHECK
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
9*Brake hoses• Check for cracks or damage.√√√√ √• Replace. Every 4 years
10 *Wheels• Check runout and for damage.√√√√
• Check tread depth and for damage.
11 *Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
12 *Wheel bearings• Check bearing for looseness or damage.√√√√
13 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 20000 km
14 *Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.√√√√ √
15Sidestand, centerstand• Check operation.
• Lubricate.√√√√ √
16 *Sidestand switch• Check operation.√√ √ √√ √
17 *Front fork• Check operation and for oil leakage.√√√√
18 *Shock absorber
• Check operation and shock absorbers for oil leakage.√√√√
assemblies
19 *Carburetor• Adjust engine idling speed.√√ √ √√ √
• Change. (See page 6-9.)√When the oil change indicator light
20Engine oilcomes on (every 3000 km)
• Check oil level and vehicle for oil leakage. Every 3000 km√
21 *Engine oil strainer• Clean.√√√
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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