belt YAMAHA MAJESTY 400 2006 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 .....................................3-4
Multi-function display .......................3-4
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-10
Fuel tank cap .................................3-11
Fuel ................................................3-12
Catalytic converter .........................3-13
Seats .............................................3-13
Adjusting the rider seat ..................3-14
Storage compartments ..................3-15
Sidestand .......................................3-17
Ignition circuit cut-off system .........3-17
PRE-OPERATION CHECKS
...............4-1Pre-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 ............................. 6-21
Tires .............................................. 6-21
Cast wheels ................................... 6-23Front and rear brake lever free
play ............................................ 6-23
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 ..... 6-33
Replacing a rear turn signal light
bulb ............................................ 6-34
Replacing the license plate light
bulb ............................................ 6-35
Troubleshooting ............................ 6-36
Troubleshooting charts ................. 6-37

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 filter element (page 6-18)
5. Owner’s tool kit (page 6-1)
6. Fuses (page 6-31)
7. Battery (page 6-30)
8. Air filter element (left) (page 6-18)9. Engine oil filter element (page 6-12)
10. Centerstand (page 6-28)
11. Sidestand (page 3-17, 6-28)

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9
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 indi-cator 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 “ON” be-
fore using the “SELECT” and “RE-
SET” buttons.

When the key is turned to “ON”, 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 “SELECT” button switches
the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP” in the following order:
ODO
→
TRIP (top)
→
TRIP (bottom)
→
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
fuel meter and fuel level warning indica-tor will start flashing, and the display will
automatically change to the fuel re-
serve tripmeter mode “TRIP F” and
start counting the distance traveled
from that point. In that case, pushing
the “SELECT” button switches the dis-
play between the various tripmeter and
odometer modes in the following order:
TRIP F
→
TRIP (top)
→
TRIP (bottom)
→
ODO
→
TRIP F
To reset a tripmeter, select it by push-
ing the “SELECT” button until “TRIP” or
“TRIP F” begins flashing (“TRIP” or
“TRIP F” will only flash for five sec-
onds). While “TRIP” or “TRIP F” is
flashing, push the “RESET” button for
at least one second. If you do not reset

1. V-belt replacement indicator “V-BELT”
2. Fuel level warning indicator “ ”
3. Coolant temperature warning indicator
“ ”
4. Oil change indicator “OIL”
123
4

1. Fuel reserve tripmeter
1

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9
the fuel reserve tripmeter manually, it
will reset itself automatically and the
display will return to the prior mode af-
ter refueling and traveling 5 km (3 mi).
NOTE:

The display cannot be changed back to
“TRIP F” after pushing the “RESET”
button.
Fuel meter
With the key in the “ON” position, the
fuel meter indicates the amount of fuel
in the fuel tank. The display segments
of the fuel meter disappear towards “E”
(Empty) as the fuel level decreases.
When the fuel level reaches the bottom
segment near “E”, the fuel level warn-
ing indicator and the bottom segment
will flash. Refuel as soon as possible.
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. The
coolant temperature varies with chang-
es in the weather and engine load. If
the top segment and coolant tempera-
ture warning indicator flash, stop thevehicle and let the engine cool. (See
page 6-37.)
CAUTION:

ECA10020
Do not operate the engine if it is
overheated.
Oil change indicator “OIL”
This indicator flashes at the initial
1000 km (600 mi), then at 5000 km
(3000 mi) and every 5000 km (3000
mi) thereafter to indicate that the en-
gine oil should be changed.
After changing the engine oil, reset the
oil change indicator. (See page 6-12.)
If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval hasbeen reached), the indicator must be
reset after the oil change for the next
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 “ ”
and turn the key to “ON”.
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
“V-BELT”
This indicator flashes every 20000 km
(12500 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can
be checked according to the following

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
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
2
3
4
5
67
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

*
Fuel injection

Check engine idle speed.
√√√√√ √
20

Engine oil

Change. (See pages 3-4 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
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.
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
6-18
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.

1. Screw
2. Air filter case cover
3. Rubber cap
1. Screw
2. Air filter case cover
3. Rubber cap
1
21
13
3
1
1
23

1. Air filter element
1. Air filter element
1
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1
2
3
4
5
6
7
8
9
6. Install the rubber cap.
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 filter check hose
1. Air filter check hose
1
1

1. Screw
2. V-belt air filter case cover
2
111

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.
EAU21381
Checking the throttle cable
free play
The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 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 filter element
2
1 1

1. Throttle cable free play
1