belt YAMAHA MAJESTY 400 2004 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: MAJESTY 400, Model: YAMAHA MAJESTY 400 2004Pages: 92, PDF Size: 2.25 MB
Page 6 of 92
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
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Speedometer ...................................3-4
Tachometer .....................................3-4
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-9
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-11
Fuel tank cap .................................3-11
Fuel ................................................3-12
Catalytic converter .........................3-13
Seats .............................................3-13
Adjusting the rider seat ..................3-15
Storage compartments ..................3-15
Sidestand .......................................3-17
Ignition circuit cut-off system .........3-17
PRE-OPERATION CHECKS
............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the 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 ............................... 5-4
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Ownerβs tool kit ................................ 6-1
Periodic maintenance and
lubrication chart ............................. 6-3
Removing and installing cowlings
and panels .................................... 6-6
Checking the spark plug ................ 6-10
Engine oil and oil filter element ..... 6-12
Final transmission oil ..................... 6-15
Coolant .......................................... 6-16
Air filter elements and check hoses
and V-belt case air filter
element ....................................... 6-18
Adjusting the throttle cable free
play ............................................. 6-20
Adjusting the valve clearance ....... 6-21Tires .............................................. 6-21
Cast wheels .................................. 6-23
Front and rear brake lever free
play ............................................. 6-24
Adjusting the rear brake lock lever
cable ........................................... 6-24
Checking the front and rear brake
pads ............................................ 6-25
Checking the brake fluid level ....... 6-25
Changing the brake fluid ............... 6-26
Checking and lubricating the
cables ......................................... 6-27
Checking and lubricating the
throttle grip and cable ................. 6-27
Lubricating the front and rear
brake levers ................................ 6-27
Checking and lubricating the
centerstand and sidestand ......... 6-28
Checking the front fork .................. 6-28
Checking the steering ................... 6-29
Checking the wheel bearings ........ 6-30
Battery ........................................... 6-30
Replacing the fuses ...................... 6-31
Replacing a headlight bulb ........... 6-33
Tail/brake light ............................... 6-33
Replacing a front turn signal light
bulb or an auxiliary light bulb ...... 6-34
Replacing a rear turn signal light
bulb ............................................. 6-35
Replacing the license plate light
bulb ............................................. 6-36
Page 14 of 92
2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
9 1
2
3
5
67
8
4
10
11
1. Headlight (page 6-33)
2. Fuel tank cap (page 3-11)
3. Rear storage compartment (page 3-15)
4. V-belt case air ο¬lter element (page 6-18)
5. Ownerβs tool kit (page 6-1)
6. Fuses (page 6-31)
7. Battery (page 6-30)
8. Air ο¬lter element (left) (page 6-18)9. Engine oil ο¬lter element (page 6-12)
10. Centerstand (page 6-28)
11. Sidestand (page 6-28)
Page 21 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9
EAU34133
Multi-function display
WARNING
EWA12311
Be sure to stop the vehicle before
making any setting changes to the
multi-function display.
The multi-function display is equipped
with the following:
a fuel meter
a coolant temperature meter
an odometer (which shows the to-
tal distance traveled)
two tripmeters (which show the
distance traveled since they were
last set to zero)
a fuel reserve tripmeter (which
shows the distance traveled since
the bottom segment of the fuel
meter and fuel level warning sym-bol started flashing)
a self-diagnosis device
a clock
an ambient temperature display
an oil change indicator
a V-belt replacement indicator
NOTE:
Be sure to turn the key to βONβ be-
fore using the βSELECTβ and βRE-
SETβ buttons.
When the key is turned to βONβ, all
of the display segments of the
multi-function display will appear
one after the other and then disap-
pear, in order to test the electrical
circuit.
Odometer and tripmeter modes
Pushing the βSELECTβ button switches
the display between the odometer
mode βODOβ and the tripmeter modes
βTRIPβ in the following order:
ODO
β
TRIP (top)
β
TRIP (bottom)
β
ODO
When approximately 2.8 L (0.74 US
gal) (0.62 Imp.gal) of fuel remains in the
fuel tank, the bottom segment of the
1. Clock/ambient temperature display
2. Coolant temperature meter
3. Fuel meter
4. Odometer/tripmeters
5. βSELECTβ button
6. βRESETβ button
1
2
3
4
5
6
1. V-belt replacement indicator βV-BELTβ
2. Fuel level warning symbol β β
3. Coolant temperature symbol β β
4. Oil change indicator βOILβ
123
4
Page 23 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
periodic oil change to be indicated at
the correct time. (See page 6-12.)
The electrical circuit of the indicator can
be checked according to the following
procedure.
1. Set the engine stop switch to β β
and turn the key to βONβ.
2. Check that the indicator comes on
for a few seconds and then goes
off.
3. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
NOTE:
The oil change indicator may flash
when the engine is revved with the
scooter on the centerstand, but this
does not indicate a malfunction.
V-belt replacement indicator
βV-BELTβ
This indicator flashes every 20000 km
(12000 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can
be checked according to the following
procedure.1. Turn the key to βONβ and make
sure that the engine stop switch is
set to β β.
2. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
Self-diagnosis device
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
multi-function display will indicate a
two-digit error code (e.g., 12, 13, 14).
If the multi-function display indicates
such an error code, note the code num-
ber, and then have a Yamaha dealer
check the vehicle.
CAUTION:
ECA11790
If the multi-function display indi-
cates an error code, the vehicle
should be checked as soon as pos-
sible in order to avoid engine dam-
age.
This model is also equipped with a
self-diagnosis device for the immobiliz-er system.
If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code (e.g., 51, 52, 53)
when the key is turned to βONβ.
NOTE:
If the multi-function display indicates er-
ror code 52, this could be caused by
transponder interference. If this error
appears, try the following.
1. Use the code re-registering key to
start the engine.
NOTE:
Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
Page 44 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
EAU17703
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
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.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
Γ
1000 km)
ANNUAL
CHECK
1 10203040
1*
Fuel line
Check fuel hoses for cracks or damage.
β
β
β
β
β
2
Spark plug
Check condition.
Clean and regap.
β
β
Replace.
β
β
3*
Valves
Check valve clearance.
Adjust.Every 40000 km
4
Air ο¬lter elements
Replace.
β
β
5
V-belt case air ο¬lter ele-
ment
Clean.
β
β
β
β
6*
Front brake
Check operation, ο¬uid level and vehicle for ο¬uid leak-
age.
β
β
β
β
β
β
Replace brake pads. Whenever worn to the limit
7*
Rear brake
Check operation, ο¬uid level and vehicle for ο¬uid leak-
age.
β
β
β
β
β
β
Replace brake pads. Whenever worn to the limit
8
Rear brake lock
Check operation.
Adjust.
β
β
β
β
β
β
9*
Brake hoses
Check for cracks or damage.
β
β
β
β
β
Replace. Every 4 years
Page 45 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9
10
*
Wheels
Check runout and for damage.
β
β
β
β
11
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
β
β
β
β
β
12
*
Wheel bearings
Check bearing for looseness or damage.
β
β
β
β
13
*
Steering bearings
Check bearing play and steering for roughness.
β
β
β
β
β
Lubricate with lithium-soap-based grease. Every 20000 km
14
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
β
β
β
β
β
15
Sidestand, centerstand
Check operation.
Lubricate.
β
β
β
β
β
16
*
Sidestand switch
Check operation.
β
β
β
β
β
β
17
*
Front fork
Check operation and for oil leakage.
β
β
β
β
18
*
Shock absorber assem-
blies
Check operation and shock absorbers for oil leakage.
β
β
β
β
19
*
Electronic fuel injection
Adjust engine idling speed.
β
β
β
β
β
β
20
Engine oil
Change. (See pages 3-5 and 6-12.)
β
When the oil change indicator ο¬ashes (every
5000 km)
Check oil level and vehicle for oil leakage. Every 5000 km
β
21
Engine oil ο¬lter element
Replace.
β
β
β
22
*
Cooling system
Check coolant level and vehicle for coolant leakage.
β
β
β
β
β
Change. Every 3 years
23
Final transmission oil
Check vehicle for oil leakage.
β
β
β
Change.
β
β
β
β
β
β
24
*
V-belt
Replace. Every 20000 km
25
*Front and rear brake
switches
Check operation.β β β β β β
26
Moving parts and cables
Lubricate.β β β β β NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (Γ 1000 km)
ANNUAL
CHECK
1 10203040
Page 46 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
1
2
3
4
5
6
7
8
9
EAU34490
NOTE:
The air filters and V-belt filter need more frequent service if you are 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.
27
*
Throttle grip housing
and cable
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
β
β
β
β
β
28
*
Lights, signals and
switches
Check operation.
Adjust headlight beam.
β
β
β
β
β
β
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
Γ
1000 km)
ANNUAL
CHECK
1 10203040
Page 59 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
2
3
4
5
67
8
9
EAU34203
Air filter elements and check
hoses and V-belt case air filter
element
The air filter elements and the V-belt
case air filter element should be ser-
viced at the intervals specified in the
periodic maintenance and lubrication
chart. Service all air filter elements
more frequently if you are riding in un-
usually wet or dusty areas.
Replacing the air filter elements
1. Place the scooter on the center-
stand.
NOTE:
Continue as follows for each air filter el-
ement.
2. Remove the air filter case cover by
removing the rubber cap and
screws.
Left
Right
3. Pull the air filter element out.
Left
Right
4. Insert a new air filter element into
the air filter case.
5. Install the air filter case cover by in-
stalling the screws.
6. Install the rubber cap.
1. Screw
2. Air ο¬lter case cover
3. Rubber cap
1. Screw
2. Air ο¬lter case cover
3. Rubber cap
1(Γ6)
21
13
3
1(Γ5)
1
23
1. Air ο¬lter element
1. Air ο¬lter element
1
1
Page 60 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1
2
3
4
5
6
7
8
9
CAUTION:
ECA12922
Make sure that each filter ele-
ment is properly seated in its
case.
Always replace both air filter el-
ements at the same time, other-
wise poor engine performance
or damage to the engine may re-
sult.
The engine should never be op-
erated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
To clean the air filter check hoses
1. Check the hose at the bottom of
both air filter cases for accumulat-
ed dirt or water.
Left
Right
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
Cleaning the V-belt case air filter el-
ement
1. Remove cowling E. (See
page 6-6.)
2. Remove panel B. (See page 6-6.)
3. Remove the V-belt air filter case
cover by removing the screws.
4. Remove the V-belt case air filter
element by removing the screws.
1. Air ο¬lter check hose
1. Air ο¬lter check hose
1
1
1. Screw
2. V-belt air ο¬lter case cover
2
11(Γ5)1
Page 61 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
2
3
4
5
67
8
9
5. Lightly tap the V-belt case air filter
element to remove most of the
dust and dirt, and then blow out the
dirt with compressed air as shown.
6. Check the V-belt case air filter ele-
ment for damage and replace it ifnecessary.
7. Install the V-belt case air filter ele-
ment by installing the screws.
8. Install the V-belt air filter case cov-
er by installing the screws.
CAUTION:
ECA12940
Make sure that the V-belt filter ele-
ment is properly seated in its case.
9. Install the panel.
10. Install the cowling.
EAU21380
Adjusting the throttle cable
free play
The throttle cable free play should mea-
sure 3.0β5.0 mm (0.12β0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
1. Screw
2. V-belt case air ο¬lter element
2
1
(Γ4)1
1. Throttle cable free play
1