YAMAHA MAJESTY 400 2011 Service Manual

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OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING

EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU48020
TIP

This model is equipped with a lean an-
gle sensor to stop the engine in case of
a turnover. In this case, the multi-func-
tion display indicates error code 30, but
this is not a malfunction. Turn the key to
“OFF” and then to “ON” to clear the er-
ror code. Failing to do so will prevent
the engine from starting even though
the engine will crank when pushing the
start switch.
EAU36515
Starting the engine
NOTICE

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.
See page 3-22 for more information.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
The following warning lights, indi-
cator light and indicators should
come on for a few seconds, then
go off.

Engine trouble warning light

ABS warning light (for ABS mod-
els)

Immobilizer system indicator light

V-belt replacement indicator

Oil change indicator
NOTICE

ECA15024
If a warning light, indicator light or
indicator does not go off, see pages
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OPERATION AND IMPORTANT RIDING POINTS
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93-3, 3-5, 3-7 or 3-8 for the corre-
sponding warning light, indicator

light or indicator circuit check.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the front
or rear brake.
If the engine does not start, re-
lease the start switch, wait a few
seconds, and then try again. Each
starting attempt should be as short
as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one at-
tempt.
NOTICE

ECA11042
For maximum engine life, never ac-
celerate hard when the engine is
cold!
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).
1. Grab bar1
(a)
(b)
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OPERATION AND IMPORTANT RIDING POINTS
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EAU16793
Braking
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.
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
Front
Rear
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).
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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 re-
place the engine oil, final transmis-
sion oil and the oil filter
element.

[ECA12931]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above6000 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17243
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle.
If you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
WARNING

EWA15121
Turn off the engine when perform-
ing maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
WARNING

EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU17502
Owner’s tool kit
The owner’s tool kit is located inside the
rear storage compartment. (See
page 3-19.)
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.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Storage compartment mat
2. Owner’s tool kit
1
2
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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
system
•Check the air cut-off valve, reed
valve, and hose for damage.
•Replace any damaged parts if
necessary.
√√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU1770C
General maintenance and lubrication chart
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
Air filter elements
•Replace.
√√
2
V-belt case air filter
element
•Clean.
√√√√
3*
Front brake
•Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
•Replace brake pads. Whenever worn to the limit
4*
Rear brake
•Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
•Replace brake pads. Whenever worn to the limit
5*
Brake hoses
•Check for cracks or damage.
•Check for correct routing and
clamping.
√√√√√
•Replace. Every 4 years
6
Rear brake lock
•Check operation.
•Adjust.
√√√√√√
7*
Wheels
•Check runout and for damage.
√√√√
8*
Tires
•Check tread depth and for
damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.
√√√√√
9*
Wheel bearings
•Check bearing for looseness or
damage.
√√√√
10 *
Steering bearings
•Check bearing play and steering
for roughness.
√√√√√
•Lubricate with
lithium-soap-based grease.Every 20000 km (12000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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11 *
Chassis fasteners
•Make sure that all nuts, bolts
and screws are properly
tightened.
√√√√√
12
Front brake lever
pivot shaft
•Lubricate with silicone grease.
√√√√√
13
Rear brake lever
pivot shaft
•Lubricate with silicone grease.
√√√√√
14
Sidestand,
centerstand
•Check operation.
•Lubricate with
lithium-soap-based grease.
√√√√√
15 *
Sidestand switch
•Check operation.
√√√√√√
16 *
Front fork
•Check operation and for oil
leakage.
√√√√
17 *
Shock absorber
assemblies
•Check operation and shock
absorbers for oil leakage.
√√√√
18
Engine oil
•Change. (See pages 3-5 and
6-12.)
√
When the oil change indicator flashes
•Check oil level and vehicle for oil
leakage.Every 5000 km (3000 mi)
√
19
Engine oil filter
element
•Replace.
√√√
20 *
Cooling system
•Check coolant level and vehicle
for coolant leakage.
√√√√√
•Change. Every 3 years
21
Final transmission
oil
•Check vehicle for oil leakage.
√√ √
•Change.
√√√√√√
22 *
V-belt
•Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
23 *
Front and rear
brake switches
•Check operation.
√√√√√√
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 ADJUSTMENT
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EAU34491
TIP


Engine air filters and V-belt air filter
•This model’s engine air filters are equipped with disposable oil-coated paper elements, which must not be cleaned
with compressed air to avoid damaging them.
•The engine air filter elements need to be replaced and the V-belt air filter element needs to be serviced more frequent-
ly when 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.
24
Moving parts and
cables
•Lubricate.
√√√√√
25 *
Throttle grip
•Check operation.
•Check throttle grip free play, and
adjust if necessary.
•Lubricate cable and grip
housing.
√√√√√
26 *
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)
✦✧✯✬✲✦ ✩