fuel YAMAHA MAJESTY 400 2009 User Guide

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.
EAU34321
0–1000 km (0–600 mi)
Avoid prolonged operation above 4000
r/min.
NOTICE:
After 1000 km (600
mi) of operation, be sure to replace
the engine oil, final transmission oil
and the oil filter element.

[ECA12931]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6000
r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE

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.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10311

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 and be burned.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.

Do not park near grass or other
flammable materials which
might catch fire.

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU46861
TIP


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.
EAU46910
Periodic maintenance chart for the emission control system
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*
Fuel injection

Check engine idle speed.
√√√√√√
5*
Air induction sys-
tem

Check the air cut-off valve, reed
valve, and hose for damage.

Replace any damaged parts if
necessary.
√√√√√

PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
EAU21873
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

EWA10501
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.

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

EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
200 kPa (2.00 kgf/cm
2

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

, 36 psi)
90–185 kg (198–408 lb):
Front:
200 kPa (2.00 kgf/cm
2

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

, 36 psi)
Maximum load*:
185 kg (408 lb)
* Total weight of rider, passenger, car-
go and accessories

PERIODIC MAINTENANCE AND ADJUSTMENT
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3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

1. Spare main fuse
2. Main fuse
3. Hazard fuse
4. ABS control unit fuse
5. ABS solenoid fuse
6. ABS motor fuse
1. Fuse box
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1. Ignition fuse
2. Signaling system fuse
3. Headlight fuse
4. Radiator fan fuse
5. Backup fuse (for odometer and clock)
6. Fuel injection system fuse
7. Spare fuse
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123456

Specified fuses:
Main fuse:
40.0 A
Ignition fuse:
10.0 A
Signaling system fuse:
10.0 A
Headlight fuse:
20.0 A
Hazard fuse:
10.0 A
Radiator fan fuse:
10.0 A
Fuel injection system fuse:
10.0 A
ABS control unit fuse:
10.0 A
ABS motor fuse:
30.0 A
ABS solenoid fuse:
20.0 A
Backup fuse:
10.0 A

PERIODIC MAINTENANCE AND ADJUSTMENT
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5. Insert a new bulb into the socket.
6. Install the license plate light lens
and license plate light cover by in-
stalling the screws.
7. Install the cowling.

EAU39020
Auxiliary light bulb
If the auxiliary light does not come on,
have a Yamaha dealer check the elec-
trical circuit or replace the bulb.
EAU25881
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your scooter re-
quire any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the scooter prop-
erly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING

EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
1. License plate light bulb
1

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EAU42701
Troubleshooting charts
Starting problems or poor engine performance
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
Operate the electric starter.

SCOOTER CARE AND STORAGE
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9plenty of water, as it is harmful
to plastic parts.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.

Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on the
roads during winter are extremely cor-
rosive in combination with water, carry
out the following steps after each ride in
the rain, near the sea or on
salt-sprayed roads.TIP

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-
gine has cooled down.
NOTICE:
Do not use warm water since it
increases the corrosive action
of the salt.
[ECA10791]

2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-

SCOOTER CARE AND STORAGE
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er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely be-
fore storing or covering it.
WARNING

EWA10941
Contaminants on the brakes or tires
can cause loss of control.

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.

Before operating the scooter
test its braking performance
and cornering behavior.
NOTICE

ECA10800

Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.

Never apply oil or wax to any
rubber and plastic parts, buttreat them with a suitable care
product.

Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP


Consult a Yamaha dealer for ad-
vice on what products to use.

Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
EAU36561
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
NOTICE

ECA10820

Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.

To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the

SCOOTER CARE AND STORAGE
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fuel from deteriorating.
3. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.

[EWA10951]

4. Lubricate all control cables and the
pivoting points of all levers andpedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than
30 °C (90 °F)]. For more informa-
tion on storing the battery, see
page 6-30.
TIP

Make any necessary repairs before
storing the scooter.

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89

SPECIFICATIONS
EAU2633X
Dimensions:
Overall length:
2230 mm (87.8 in)
Overall width:
780 mm (30.7 in)
Overall height:
1380 mm (54.3 in)
Seat height:
760 mm (29.9 in)
Wheelbase:
1565 mm (61.6 in)
Ground clearance:
120 mm (4.72 in)
Minimum turning radius:
2600 mm (102.4 in)
Weight:
With oil and fuel:
223.0 kg (492 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
395 cm
3

Bore
×
stroke:
83.0
×
73.0 mm (3.27
×
2.87 in)
Compression ratio:
10.60 :1
Starting system:
Electric starter
Lubrication system:
Wet sump

Engine oil:
Recommended brand:
YAMALUBE
Type:
SAE 10W-30, SAE 10W-40, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO stan-
dard MA
Engine oil quantity:
Without oil filter element replacement:
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter element replacement:
1.70 L (1.80 US qt, 1.50 Imp.qt)
Final transmission oil:
Type:
YAMALUBE 10W-40 or SAE 10W-30 type
SE motor oil
Quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.32 L (0.34 US qt, 0.28 Imp.qt)
Radiator capacity (including all routes):
1.57 L (1.66 US qt, 1.38 Imp.qt)
Air filter:
Air filter element:
Oil-coated paper element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.0 L (3.70 US gal, 3.08 Imp.gal)
Fuel injection:
Throttle body:
ID mark:
5RUG 20
Spark plug (s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
31/14 (2.214)
Secondary reduction system:
Helical gear
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50