YAMAHA MAJESTY 400 2008 Service Manual

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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
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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)

OPERATION AND IMPORTANT RIDING POINTS
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9 Rear
WARNING

EWA10300

Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the scooter
may skid or overturn.

Railroad crossings, streetcar
rails, iron plates on road con-
struction sites, and manhole
covers become extremely slip-
pery when wet. Therefore, slow
down when approaching such
areas and cross them with cau-
tion.

Keep in mind that braking on a
wet road is much more difficult.

Ride slowly down a hill, as brak-ing downhill can be very diffi-
cult.
EAU16820
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Avoid high engine speeds during
acceleration.

Avoid high engine speeds with no
load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).

OPERATION AND IMPORTANT RIDING POINTS
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EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU34320
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
CAUTION:

ECA12930
After 1000 km (600 mi) of operation,be sure to replace the engine oil, fi-
nal transmission oil and the oil filter
element.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

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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 3-17.)
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
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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
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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
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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
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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
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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.