engine YAMAHA MAJESTY 400 2011 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
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EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU34321
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
NOTICE:
After 1000 km
(600 mi) of operation, be sure to re-
place the engine oil, final transmis-
sion oil and the oil filter
element.

[ECA12931]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above6000 r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10311

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.

Do not park near grass or other
flammable materials which
might catch fire.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17243
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle.
If you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
WARNING

EWA15121
Turn off the engine when perform-
ing maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
WARNING

EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46861
TIP


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
EAU46910
Periodic maintenance chart for the emission control system
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*
Fuel line
•Check fuel hoses for cracks or
damage.
√√√√√
2
Spark plug
•Check condition.
•Clean and regap.
√√
•Replace.
√√
3*
Valves
•Check valve clearance.
•Adjust.Every 40000 km (24000 mi)
4*
Fuel injection
•Check engine idle speed.
√√√√√√
5*
Air induction
system
•Check the air cut-off valve, reed
valve, and hose for damage.
•Replace any damaged parts if
necessary.
√√√√√
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11 *
Chassis fasteners
•Make sure that all nuts, bolts
and screws are properly
tightened.
√√√√√
12
Front brake lever
pivot shaft
•Lubricate with silicone grease.
√√√√√
13
Rear brake lever
pivot shaft
•Lubricate with silicone grease.
√√√√√
14
Sidestand,
centerstand
•Check operation.
•Lubricate with
lithium-soap-based grease.
√√√√√
15 *
Sidestand switch
•Check operation.
√√√√√√
16 *
Front fork
•Check operation and for oil
leakage.
√√√√
17 *
Shock absorber
assemblies
•Check operation and shock
absorbers for oil leakage.
√√√√
18
Engine oil
•Change. (See pages 3-5 and
6-12.)
√
When the oil change indicator flashes
•Check oil level and vehicle for oil
leakage.Every 5000 km (3000 mi)
√
19
Engine oil filter
element
•Replace.
√√√
20 *
Cooling system
•Check coolant level and vehicle
for coolant leakage.
√√√√√
•Change. Every 3 years
21
Final transmission
oil
•Check vehicle for oil leakage.
√√ √
•Change.
√√√√√√
22 *
V-belt
•Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
23 *
Front and rear
brake switches
•Check operation.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU34491
TIP


Engine air filters and V-belt air filter
•This model’s engine air filters are equipped with disposable oil-coated paper elements, which must not be cleaned
with compressed air to avoid damaging them.
•The engine air filter elements need to be replaced and the V-belt air filter element needs to be serviced more frequent-
ly when riding in unusually wet or dusty areas.

Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
•Replace the brake hoses every four years and if cracked or damaged.
24
Moving parts and
cables
•Lubricate.
√√√√√
25 *
Throttle grip
•Check operation.
•Check throttle grip free play, and
adjust if necessary.
•Lubricate cable and grip
housing.
√√√√√
26 *
Lights, signals and
switches
•Check operation.
•Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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the original position.

EAU47890
Panel A
To remove the panel
Remove the screws, and then pull the
panel outward.
To install the panelPlace the panel in the original position,
and then install the screws.

EAU34173
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Open the rider seat. (See
page 3-17.)
2. Pull up the storage compartment
mat, and then remove the spark
plug cover by removing the
screws.
1. Panel A
2. Screw
21

1. Screw
2. Panel A
12
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3. Remove the spark plug cap.
4. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIP

If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it ifnecessary.
3. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
To install the spark plug
1. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
1. Storage compartment mat
2. Spark plug cover
3. Screw
1. Spark plug cap
1
2
3
1

1. Spark plug wrench
1

Specified spark plug:
NGK/CR7E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
1
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2. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIP

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. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
3. Install the spark plug cap.
TIP

Make sure the spark plug wire is fas-
tened in the clamp as shown.4. Install the spark plug cover by in-
stalling the screws.
5. Place the storage compartment
mat in the original position.
6. Close the rider seat.
EAU34187
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart and when the oil change in-
dicator comes on.
To check the engine oil level
1. Place the vehicle on the center-
stand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
TIP

The engine oil should be between the
tip of the dipstick and the maximum lev-
el mark.
Tightening torque:
Spark plug:
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
1. Spark plug cap
2. Spark plug wire clamp
3. Spark plug wire
1
2 3
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4. If the engine oil is not between the
tip of the dipstick and the maxi-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Place the vehicle on the center-
stand.2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap,
the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
TIP

Skip steps 5–7 if the oil filter element is
not being replaced.
5. Remove the oil filter element cover
by removing the bolts.
NOTICE:
When removing the oil filter ele-ment cover, the compression
spring will fall out. Take care not
to lose the compression
spring.
[ECA12911]

6. Remove and replace the oil filter
element and O-rings.
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Tip of the engine oil dipstick
34
1
2

1. Engine oil drain bolt
2. Gasket
12

1. Bolt
2. Oil filter element cover
21
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7. Install the compression spring and
oil filter element cover by installing
the bolts, then tightening them to
the specified torque.
TIP

Make sure that the O-rings are properly
seated.
8. Install the engine oil drain bolt and
its new gasket, and then tightenthe bolt to the specified torque.
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIP

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
NOTICE

ECA11670

Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled“ENERGY CONSERVING II” or
higher.

Be sure no foreign material en-
ters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
11. Reset the oil change indicator ac-
cording to the following procedure.
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button
pushed for two to eight seconds.
3. Release the “OIL CHANGE” but-

1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
24
3

Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter element replacement:
1.70 L (1.80 US qt, 1.50 Imp.qt)

1.“OIL CHANGE” button
1
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