warning YAMAHA MAJESTY 400 2005 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
2
3
4
5
67
8
9
NOTE:

The coolant should be between the
minimum and maximum level marks.
5. If the coolant is at or below the
minimum level mark, open the
coolant reservoir cap, add coolant
to the maximum level mark, and
then close the coolant reservoir
cap.
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.

If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
6. Install the coolant reservoir cover
by installing the screw.7. Place the right floorboard mat in
the original position.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-37 for further instructions.
1. Minimum level mark
2. Maximum level mark
3. Coolant reservoir cap
Coolant reservoir capacity (up to
the maximum level mark):
0.32 L (0.34 US qt) (0.28 Imp.qt)
1
2
3

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
2
3
4
5
67
8
9

EAU21401
Valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU33600
Tires
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA10500

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
WARNING

EWA11200
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your vehicle, you should keep
the following precautions in mind.

NEVER OVERLOAD THE VEHI-
CLE! Operation of an overload-
ed vehicle may result in tire
damage, loss of control, or se-
vere injury. Make sure that the
total weight of rider, passenger,
Tire air pressure (measured on cold
tires):
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

)
90–194 kg (198–428 lb) :
Front:
200 kPa (29 psi) (2.00 kgf/cm
2

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

)
Maximum load*:
194 kg (428 lb)
* Total weight of rider, passenger, car-
go and accessories

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
2
3
4
5
6
7
8
9cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.

Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.

Adjust the tire air pressure with
regard to the load.

Check the tire condition and air
pressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This model is equipped with tubeless
tires.
WARNING

EWA10470

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
12

Front tire:
Size:
120/80-14M/C 58S
Manufacturer/model:
IRC/MB67
DUNLOP/D305FL
Rear tire:
Size:
150/70-13M/C 64S
Manufacturer/model:
IRC/MB67
DUNLOP/D305L

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
1
2
3
4
5
6
7
8
9

EAU33451
Front and rear brake lever free
play
Front
Rear
There should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
EAU33473
Adjusting the rear brake lock
lever cable
Rear brake lock lever cable adjustment
may be required if the rear brake lock le-
ver does not hold properly. When the
rear brake lock lever is not in use, the
rear brake lock lever cable length should
measure 45 mm to 47 mm (1.77 in to
1.85 in) at the rear brake caliper. Period-
ically check the rear brake lock lever ca-
ble length and, if necessary, adjust it as
follows.
To increase the rear brake lock lever
cable length, turn the adjusting nut atthe rear brake caliper in direction (a).
To decrease the rear brake lock lever
cable length, turn the adjusting nut in
direction (b).
WARNING

EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
1. Adjusting nut
2. Rear brake lock lever cable length
1
2
(a) (b)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
2
3
4
5
67
8
9

EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
EAU23110
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23170
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
1
2
3
4
5
6
7
8
9

EAU23210
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and met-
al-to-metal contact surfaces should be
lubricated if necessary.
WARNING

EWA10740
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
2
3
4
5
67
8
9
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
1
2
3
4
5
6
7
8
9

EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU34221
Battery
The battery is located behind cowling
A. (See page 6-6.)
This model is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
WARNING

EWA10760

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes whenworking near batteries. In case
of contact, administer the fol-
lowing FIRST AID.

EXTERNAL: Flush with plenty
of water.

INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.

EYES: Flush with water for 15
minutes and seek prompt
medical attention.

Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.

KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
1. Battery
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
2
3
4
5
67
8
9

EAU25921
Troubleshooting charts
Starting problems or poor engine
performance
WARNING

EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
1
2
3
4
5
6
7
8
9Engine overheating
WARNING

EWA10400

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.