2004 YAMAHA MAJESTY 400 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU18711
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.
EAU34281
Cowling A
To remove the cowling
1. Open the rider seat. (See
page 3-13.)
2. Remove the quick fasteners in the
rear storage compartment, and
then pull the cowling off as shown.NOTE:

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.NOTE:

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.
Cowling B
To remove the cowling
1. Remove the screws.

1. Panel A
2. Cowling C
3. Cowling A
4. Cowling B
5. Panel B
6. Cowling E
2
3
4
5
6 1

1. Cowling D
1

1. Quick fastener
2. Cowling A
1
2

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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 cowlings
1. Remove cowlings A and B.
2. Remove the passenger seat. (See
page 3-13.)
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
2
1

1. Grab bar bolt
2. Collar
3. Grab bar
1(×4)
3
1
2(×4)
2

1. Screw access cover
1. Screw
1
1
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 tabs on the cowling 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(×4)

1. Cowling E
1. Tab
1
1(×13)
1

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EAU34290
Panel A
To remove the panel
1. Remove the bolts.
2. Pull the panel out as shown.
To install the panelPlace the panel in the original position,and then install the bolts.
Panel B
To remove the panel
Remove the screws, and then pull the
panel outward.To install the panel
Place the panel in the original position,
and then install the screws.

1. Bolt
2. Panel A
2
1

1. Panel B
2. Screw
21

1. Screw
2. Panel B
12

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EAU34171
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 3-13.)
2. Pull up the storage compartment
mat, and then remove the spark
plug cover by removing the
screws.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).
NOTE:

If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
1. Storage compartment mat
2. Spark plug cover
3. Screw
1. Spark plug cap
1
2
3(×3)
1

1. Spark plug wrench
1

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

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.
NOTE:

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

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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EAU34181
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.
NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
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 itagain to check the oil level.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
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.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
1
2
3
1

1. Engine oil drain bolt
1

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NOTE:

Skip steps 5–7 if the oil filter element is
not being replaced.
5. Remove the oil filter element cover
by removing the bolts.6. Remove and replace the oil filter
element and O-rings.
CAUTION:

ECA12910
When removing the oil filter element
cover, the compression spring will
fall out. Take care not to lose the
compression spring.
7. Install the compression spring and
oil filter element cover by installing
the bolts, then tightening them to
the specified torque.
1. Engine oil drain bolt
2. Washer
2
1

1. Bolt
2. Oil filter element cover
21
(×3)

1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
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4