brake YAMAHA MAJESTY 400 2008 User Guide

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15605
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-14
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-13
Final transmission oil

Check vehicle for oil leakage. 6-16
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-17
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-26
Rear brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-26
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-22, 6-29

PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9

Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-22, 6-24
Brake levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-29
Centerstand, sidestand

Make sure that operation is smooth.

Lubricate pivots if necessary.6-29
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Instruments, lights, signals
and switches

Check operation.

Correct if necessary.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-19
ITEM CHECKS PAGE

5-1
2
3
4
56
7
8
9

OPERATION AND IMPORTANT RIDING POINTS
EAU15980
WARNING

EWA10870

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

For safety, always start the en-
gine with the centerstand down.
EAU34460
Starting the engine
CAUTION:

ECA10250
See page 5-4 for engine break-in in-
structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-20.

Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the front
or rear brake.
NOTE:

If the engine does not start, release thestart switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!

OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9

EAU45091
Starting off
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the scooter off the centerstand.
2. Sit astride the seat, and then ad-
just the rear view mirrors.
3. Switch the turn signals on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signals off.
EAU16780
Acceleration and deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throt-
tle grip in direction (b).
EAU16792
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
Front
1. Grab bar
1
(a)(b)

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

EAU1770A
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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 (24000 mi)
4
Air filter elements

Replace.
√√
5
V-belt case air filter
element

Clean.
√√√√
6*
Front brake

Check operation, fluid level
and vehicle for fluid leakage.
√√√√√√

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

Check operation, fluid level
and vehicle for fluid leakage.
√√√√√√

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

Check operation.

Adjust.
√√√√√√

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

9*
Brake hoses

Check for cracks or damage.
√√√√√

Replace. Every 4 years
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 steer-
ing for roughness.
√√√√√

Lubricate with lith-
ium-soap-based grease.Every 20000 km (12000 mi)
14

*
Chassis fasteners

Make sure that all nuts, bolts
and screws are properly tight-
ened.
√√√√√
15

Front brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
16

Rear brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
17

Sidestand, center-
stand

Check operation.

Lubricate.
√√√√√
18

*
Sidestand switch

Check operation.
√√√√√√
19

*
Front fork

Check operation and for oil
leakage.
√√√√
20

*
Shock absorber
assemblies

Check operation and shock
absorbers for oil leakage.
√√√√
21

*
Fuel injection

Check engine idle speed.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

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

22

Engine oil

Change. (See pages 3-5 and
6-13.)
√
When the oil change indicator flashes [every 5000 km (3000 mi)]

Check oil level and vehicle for
oil leakage.Every 5000 km (3000 mi)
√
23

Engine oil filter ele-
ment

Replace.
√√√
24

*
Cooling system

Check coolant level and vehi-
cle for coolant leakage.
√√√√√

Change. Every 3 years
25

Final transmission
oil

Check vehicle for oil leakage.
√√ √

Change.
√√√√√√
26

*
V-belt

Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
27

*
Front and rear brake
switches

Check operation.
√√√√√√
28

Moving parts and
cables

Lubricate.
√√√√√
29

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
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.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
1
2
3
4
5
6
7
8
9Tire 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-
edge and experience.
EAU21992
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends, warpage or
damage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.

After repairing or replacing the rear
tire, tighten the valve stem nut and
locknut to the specified torques.
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
6-25
2
3
4
5
67
8
9

EAU33453
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.
WARNING

EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re-
sult in loss of control and an acci-
dent.
1. Valve stem nut
2. Valve stem locknut
Tightening torques:
Valve stem nut:
2.0 Nm (0.2 m·kgf, 1.4 ft·lbf)
Valve stem locknut:
3.0 Nm (0.3 m·kgf, 2.2 ft·lbf)
1
2

1. Brake lever free play
1. Brake lever free play
1
1