YAMAHA MAJESTY 400 2004 Manual Online

SCOOTER CARE AND STORAGE
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9 scratched, use a quality plastic
polishing compound after

washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on the
roads during winter are extremely cor-
rosive in combination with water, carry
out the following steps after each ride in
the rain, near the sea or on
salt-sprayed roads.NOTE:

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-gine has cooled down.
CAUTION:

ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely be-
fore storing or covering it.
WARNING

EWA10940

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.

Before operating the scooter
test its braking performance
and cornering behavior.
CAUTION:

ECA10800

Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.

Never apply oil or wax to any
rubber and plastic parts, but

SCOOTER CARE AND STORAGE
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8
9treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:

Consult a Yamaha dealer for advice on
what products to use.
EAU26300
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
CAUTION:

ECA10820

Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.

To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into thefuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.

SCOOTER CARE AND STORAGE
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9
WARNING

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
5. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
8. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more in-
formation on storing the battery,
see page 6-30.
NOTE:

Make any necessary repairs before
storing the scooter.

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SPECIFICATIONS
EAU26333
Dimensions:
Overall length:
2230 mm (87.8 in)
Overall width:
780 mm (30.7 in)
Overall height:
1380 mm (54.3 in)
Seat height:
750 mm (29.5 in)
Wheelbase:
1565 mm (61.6 in)
Ground clearance:
120 mm (4.72 in)
Minimum turning radius:
2600 mm (102.4 in)
Weight:
With oil and fuel:
210.0 kg (463 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
394.9 cm
3

(24.10 cu.in)
Bore
×
stroke:
83.0
×
73.0 mm (3.27
×
2.87 in)
Compression ratio:
10.60 :1
Starting system:
Electric starter
Lubrication system:
Wet sump

Engine oil:
Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element replacement:
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)
Final transmission oil:
Type:
SAE10W30 type SE motor oil
Quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.32 L (0.34 US qt) (0.28 Imp.qt)
Radiator capacity (including all routes):
1.57 L (1.66 US qt) (1.38 Imp.qt)
Air filter:
Air filter element:
Oil-coated paper element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
Electronic fuel injection:
Manufacturer:
AISAN
Model:
1100-87C00-A
Spark plug(s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
31/14 (2.214)
Secondary reduction system:
Helical gear
Secondary reduction ratio:
42/16 (2.625)
Transmission type:
V-belt automatic
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40

SPECIFICATIONS
8-2
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89

Operation:
Centrifugal automatic type
Chassis:
Frame type:
Steel tube backbone
Caster angle:
27.00 °
Trail:
100.0 mm (3.94 in)
Front tire:
Type:
Tubeless
Size:
120/80-14M/C 58S
Manufacturer/model:
IRC/MB67
Manufacturer/model:
DUNLOP/D305FL
Rear tire:
Type:
Tubeless
Size:
150/70-13M/C 64S
Manufacturer/model:
IRC/MB67
Manufacturer/model:
DUNLOP/D305L
Loading:
Maximum load:
198 kg (437 lb)
* (Total weight of rider, passenger, cargo
and accessories)

Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
200 kPa (29 psi) (2.00 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
Loading condition:
90–198 kg (198–437 lb)
Front:
200 kPa (29 psi) (2.00 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
Front wheel:
Wheel type:
Cast wheel
Rim size:
14 x MT3.00
Rear wheel:
Wheel type:
Cast wheel
Rim size:
13 x MT4.00
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
107.0 mm (4.21 in)
Rear suspension:
Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
104.0 mm (4.09 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 Ah

SPECIFICATIONS
8-3
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9Headlight:

Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 60 W/55.0 W
×
2
Tail/brake light:
LED
Front turn signal light:
12 V, 21.0 W
×
2
Rear turn signal light:
12 V, 21.0 W
×
2
Auxiliary light:
12 V, 5.0 W
×
2
Licence plate light:
12 V, 5.0 W
×
1
Meter lighting:
12 V, 2.0 W
×
3
High beam indicator light:
12 V, 1.4 W
×
1
Turn signal indicator light:
12 V, 1.4 W
×
2
Engine trouble warning light:
12 V, 1.4 W
×
1
Immobilizer system indicator light:
LED

Fuses:
Main fuse:
40.0 A
Headlight fuse:
25.0 A
Signaling system fuse:
10.0 A Ignition fuse:
10.0 A
Radiator fan fuse:
10.0 A
Hazard fuse:
10.0 A
Electronic fuel injection fuse:
10.0 A
Backup fuse:
10.0 A

CONSUMER INFORMATION
9-1
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EAU26351
Identification numbers
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION NUM-
BER:
MODEL LABEL INFORMATION:
EAU26381
Key identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
EAU26410
Vehicle identification number
The vehicle identification number is
stamped into the frame.
NOTE:

The vehicle identification number is
used to identify your vehicle and may
be used to register it with the licensing
authority in your area.
1. Key identification number
2. Code re-registering key (red bow)
3. Standard keys (black bow)
1. Vehicle identification number
1

CONSUMER INFORMATION
9-2
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2
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4
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6
7
8
9

EAU26500
Model label
The model label is affixed to the inside
of the rear storage compartment. (See
page 3-15.) Record the information on
this label in the space provided. This in-
formation will be needed when ordering
spare parts from a Yamaha dealer.
1. Model label
1

INDEX
A
Acceleration and deceleration ...................5-2
Air filter elements and check hoses and
V-belt case air filter element ..................6-18
Anti-theft alarm (optional) ..........................3-8
B
Battery .....................................................6-30
Brake fluid, changing ...............................6-26
Brake fluid level, checking .......................6-25
Brake lever, front .....................................3-10
Brake lever, rear ......................................3-10
Brake levers, lubricating ..........................6-27
Braking ......................................................5-2
C
Cables, checking and lubricating .............6-27
Care ...........................................................7-1
Catalytic converter ...................................3-13
Centerstand and sidestand, checking
and lubricating .......................................6-28
Coolant ....................................................6-16
Cowlings and panels, removing and
installing ..................................................6-6
D
Dimmer switch ...........................................3-9
E
Engine break-in .........................................5-4
Engine oil and oil filter element ................6-12
Engine stop switch.....................................3-9
Engine trouble warning light ......................3-3
F
Final transmission oil ...............................6-15
Front and rear brake lever free play ........6-24
Front and rear brake pads, checking .......6-25
Front fork, checking .................................6-28Fuel ......................................................... 3-12
Fuel consumption, tips for reducing .......... 5-3
Fuel tank cap ........................................... 3-11
Fuses, replacing ...................................... 6-31
H
Handlebar switches ................................... 3-9
Hazard switch ............................................ 3-9
Headlight bulb, replacing ......................... 6-33
High beam indicator light ........................... 3-3
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-17
Immobilizer system.................................... 3-1
Immobilizer system indicator light ............. 3-3
Indicator and warning lights....................... 3-3
K
Key identification number .......................... 9-1
L
License plate light bulb, replacing ........... 6-36
M
Main switch/steering lock .......................... 3-2
Model label ................................................ 9-2
Multi-function display ................................. 3-5
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-3
Pre-operation check list ............................. 4-2
R
Rear brake lock lever .............................. 3-11
Rear brake lock lever cable, adjusting .... 6-24Rider seat, adjusting ............................... 3-15
S
Safe-riding points ...................................... 1-4
Safety information ..................................... 1-1
Seats ....................................................... 3-13
Sidestand ................................................ 3-17
Spark plug, checking ............................... 6-10
Specifications ............................................ 8-1
Speedometer............................................. 3-4
Starting off ................................................. 5-2
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-29
Storage...................................................... 7-3
Storage compartments ............................ 3-15
T
Tachometer ............................................... 3-4
Tail/brake light ......................................... 6-33
Throttle cable free play, adjusting ........... 6-20
Throttle grip and cable, checking and
lubricating ............................................. 6-27
Tires ........................................................ 6-21
Tool kit....................................................... 6-1
Troubleshooting ...................................... 6-36
Troubleshooting charts............................ 6-37
Turn signal indicator lights ........................ 3-3
Turn signal light bulb (front) or
auxiliary light bulb, replacing ................. 6-34
Turn signal light bulb (rear), replacing..... 6-35
Turn signal switch ..................................... 3-9
V
Valve clearance, adjusting ...................... 6-21
Vehicle identification number .................... 9-1

INDEX
W
Wheel bearings, checking ....................... 6-30
Wheels .................................................... 6-23