maintenance YAMAHA MAJESTY 400 2005 Owners Manual

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 .....................................3-5
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-9
Handlebar switches .........................3-9
Front brake lever ...........................3-11
Rear brake lever ............................3-11
Rear brake lock lever .....................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Catalytic converter .........................3-14
Seats .............................................3-14
Adjusting the rider seat ..................3-15
Storage compartments ..................3-16
Sidestand .......................................3-18
Ignition circuit cut-off system .........3-18
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
Owner’s 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
Checking the throttle cable free
play ............................................ 6-20
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

1-1
1
SAFETY INFORMATION
EAU10260
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 OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS 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 MAN-
UAL.

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 auto-
mobile/scooter accidents. Many
accidents have been caused by an
automobile driver who did not see
the scooter. Making yourself con-
spicuous appears to be very effec-
tive in reducing the chance of this
type of accident.

Therefore:

Wear a brightly colored jacket.

Use extra caution when ap-
proaching and passing through
intersections, since intersec-
tions are the most likely places
for scooter accidents to occur.

Ride where other motorists cansee you. Avoid riding in another
motorist’s blind spot.

Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent driver’s license.

Make sure that you are qualified
and that you only lend your
scooter to other qualified opera-
tors.

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 con-
trols.

Many accidents have been caused
by error of the scooter operator. A
typical error made by the operator
is veering wide on a turn due to
EXCESSIVE SPEED or undercor-
nering (insufficient lean angle for

INSTRUMENT AND CONTROL FUNCTIONS
3-13
2
34
5
6
7
8
9
move it.
3. Close the lid.
WARNING

EWA11120
Be sure that the fuel tank cap is
properly installed and locked before
riding the scooter.
EAU13210
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING

EWA10880

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.

Avoid spilling fuel on the hot en-
gine.
CAUTION:

ECA10070
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-
es or plastic parts.
EAU33520
CAUTION:

ECA11400
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 system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
1. Fuel tank filler tube
2. Fuel level
21

Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)

INSTRUMENT AND CONTROL FUNCTIONS
3-14
1
2
3
4
5
6
7
8
9

EAU13440
Catalytic converter
This vehicle is equipped with a catalytic
converter in the muffler.
WARNING

EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-
ing any maintenance work.
CAUTION:

ECA10700
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 pos-
sible fire hazards such as grass
or other materials that easily
burn.

Do not allow the engine to idle
too long.
EAU34140
Seats
Rider seat
To open the rider seat
1. Place the scooter on the center-
stand.
2. Insert the key into the main switch,
and then turn it counterclockwise.
NOTE:

Do not push inward when turning the
key.
3. Fold the rider seat up.
1. Rider seat
2. Passenger seat
2 1

1. Open.
1. Rider seat
1
1

6-1
2
3
4
5
67
8
9

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17280
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
WARNING

EWA10330
This scooter is designed for use on
paved roads only. If this scooter isoperated in abnormally dusty, mud-
dy or wet conditions, the air filter el-
ement should be cleaned or
replaced more frequently, otherwise
rapid engine wear may result. Con-
sult a Yamaha dealer for proper
maintenance intervals.
EAU17501
Owner’s tool kit
The owner’s tool kit is located inside the
rear storage compartment. (See
page 3-16.)
Pull up the storage compartment mat,
and then remove the owner’s tool kit.
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 preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
1. Storage compartment mat
2. Owner’s tool kit
1
2

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

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
WARNING

EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.

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

EAU17705
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 (
×
1000 km)
ANNUAL
CHECK
1 10203040
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
4
Air filter elements

Replace.
√√
5
V-belt case air filter ele-
ment

Clean.
√√√√
6*
Front brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
8
Rear brake lock

Check operation.

Adjust.
√√√√√ √
9*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years

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

10

*
Wheels

Check runout and for damage.
√√√√
11

*
Tires

Check tread depth and for damage.

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.
√√√√ √
15

Sidestand, centerstand

Check operation.

Lubricate.
√√√√ √
16

*
Sidestand switch

Check operation.
√√√√√ √
17

*
Front fork

Check operation and for oil leakage.
√√√√
18

*
Shock absorber assem-
blies

Check operation and shock absorbers for oil leakage.
√√√√
19

*
Electronic fuel injection

Adjust engine idling speed.
√√√√√ √
20

Engine oil

Change. (See pages 3-5 and 6-12.)
√
When the oil change indicator flashes (every
5000 km)

Check oil level and vehicle for oil leakage. Every 5000 km
√
21

Engine oil filter element

Replace.
√√√
22

*
Cooling system

Check coolant level and vehicle for coolant leakage.
√√√√ √

Change. Every 3 years
23

Final transmission oil

Check vehicle for oil leakage.
√√ √

Change.
√√√√√ √
24

*
V-belt

Replace.When the V-belt replacement indicator flashes (every
20000 km)
25

*
Front and rear brake
switches

Check operation.
√√√√√ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
2
3
4
5
67
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.
26

Moving parts and cables

Lubricate.
√√√√ √
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.
√√√√ √
28

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

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

EAU18711
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAU34281
Cowling A
To remove the cowling
1. Open the rider seat. (See
page 3-14.)
2. Remove the quick fasteners in the
rear storage compartment, and
then pull the cowling off as shown.NOTE:

The quick fastener is removed by push-
ing the center pin in with a screwdriver,
and then pulling the fastener out.To install the cowling
1. Place the cowling in the original
position, and then install the quick
fasteners.NOTE:

To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush with
the fastener head.
2. Close the rider seat.
Cowling B
To remove the cowling
1. Remove the screws.

1. Panel A
2. Cowling C
3. Cowling A
4. Cowling B
5. Panel B
6. Cowling E
2
3
4
5
6 1

1. Cowling D
1

1. Quick fastener
2. Cowling A
1
2