YAMAHA MAJESTY 400 2009 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU18712
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.
EAU34282
Cowling A
To remove the cowling
1. Open the rider seat. (See
page 3-17.)
2. Remove the quick fasteners in the
rear storage compartment, and
then pull the cowling off as shown.TIP

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.TIP

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

1. Cowling D1

1. Quick fastener
2. Cowling A
1
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9Cowling B
To remove the cowling
1. Remove the screws.
2. Remove the cowling as shown.To install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
Cowlings C and D
To remove one of the cowlings1. Remove cowlings A and B.
2. Remove the passenger seat. (See
page 3-17.)
3. Remove the grab bar by removing
the grab bar bolts and collars.
4. Remove the screw access cover
by pulling it off.5. Remove the screws, and then pull
the cowling off.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.

1. Cowling B
2. Screw
1. Cowling B
1
21

1. Grab bar bolt
2. Collar
3. Grab bar
1
1
12
2
1223

1. Screw access cover
1. Screw
1
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2. Install the screw access cover by
placing it in its original position.
3. Install the grab bar by installing the
collars and grab bar bolts.
4. Install the passenger seat.
5. Install cowlings A and B.
Cowling E
To remove the cowling
1. Pull up the left floorboard mats as
shown.2. Remove the cowling screws.
3. Pull the cowling down slightly, and
then pull it outward as shown.To install the cowling
1. Insert the projections on the cowl-
ing into the slots as shown, and
then install the screws.
2. Place the left floorboard mats in
the original position.

Tightening torque:
Grab bar bolt:
23 Nm (2.3 m·kgf, 16.6 ft·lbf)
1. Left floorboard mat
1. Screw
1
1

1. Cowling E
1. Projection
1
1
1

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EAU47890
Panel A
To remove the panel
Remove the screws, and then pull the
panel outward.
To install the panelPlace the panel in the original position,
and then install the screws.

EAU34172
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Open the rider seat. (See
page 3-17.)
2. Pull up the storage compartment
mat, and then remove the spark
plug cover by removing the
screws.
1. Panel A
2. Screw
21

1. Screw
2. Panel A
12

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3. Remove the spark plug cap.
4. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIP

If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replaceit if necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
1. Storage compartment mat
2. Spark plug cover
3. Screw
1. Spark plug cap
1
2
3
1

1. Spark plug wrench
1

Specified spark plug:
NGK/CR7E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
1

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3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIP

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
TIP

Make sure the spark plug wire is fas-
tened in the clamp as shown.5. Install the spark plug cover by in-
stalling the screws.
6. Place the storage compartment
mat in the original position.
7. Close the rider seat.
EAU34184
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart and when the oil change in-
dicator comes on.
To check the engine oil level
1. Place the vehicle on the center-
stand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
TIP

The engine oil should be between the
minimum and maximum level marks.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)
1. Spark plug cap
2. Spark plug wire clamp
1
2

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4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
4. Check the washer for damage and
replace it if necessary.
TIP

Skip steps 5–7 if the oil filter element is
not being replaced.
5. Remove the oil filter element cover
by removing the bolts.
NOTICE:
When removing the oil filter ele-
ment cover, the compression
spring will fall out. Take care not
to lose the compression
spring.
[ECA12911]

1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1
3
4
1
2

1. Engine oil drain bolt
1

1. Engine oil drain bolt
2. Washer
2
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6. Remove and replace the oil filter
element and O-rings.7. Install the compression spring and
oil filter element cover by installing
the bolts, then tightening them to
the specified torque.
TIP

Make sure that the O-rings are properly
seated.
8. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
TIP

Make sure that the washer is properly
seated.
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIP

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
NOTICE

ECA11670

Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Be sure no foreign material en-
ters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
1. Bolt
2. Oil filter element cover
1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
21
1
2
3
4

Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
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)

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11. Reset the oil change indicator ac-
cording to the following procedure.
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the “OIL CHANGE” button
pushed for two to eight seconds.
3. Release the “OIL CHANGE” but-
ton, and the oil change indicator
will go off.
TIP

If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval has
been reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated atthe correct time. To reset the oil change
indicator before the periodic oil change
interval has been reached, follow the
above procedure, but note that the indi-
cator will come on for 1.4 seconds after
releasing the “OIL CHANGE” button,
otherwise repeat the procedure.
EAU20064
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm up the final
transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the center-
stand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and final transmission
drain bolt to drain the oil from the fi-
nal transmission case.
1.“OIL CHANGE” button
1

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5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.
6. Refill with the specified amount of
the recommended final transmis-
sion oil, and then install and tighten
the oil filler cap.
WARNING! Make
sure that no foreign material en-
ters the final transmission case.
Make sure that no oil gets on the
tire or wheel.

[EWA11311]
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU34193
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Pull up the right floorboard mat as
shown.
1. Final transmission oil filler cap
2. Final transmission oil drain bolt
Tightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
2
1

Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)