2004 YAMAHA MAJESTY 400 check engine

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WARNING

EWA11310

Make sure that no foreign mate-
rial enters the final transmission
case.

Make sure that no oil gets on the
tire or wheel.
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.
EAU34191
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:


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.3. Remove the coolant reservoir cov-
er by removing the screw.
4. Check the coolant level in the cool-
ant reservoir. Recommended final transmis-
sion oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt)
(0.22 Imp.qt)
1. Right floorboard mat
1. Screw
2. Coolant reservoir cover
1
1
2

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NOTE:

The coolant should be between the
minimum and maximum level marks.
5. If the coolant is at or below the
minimum level mark, open the
coolant reservoir cap, add coolant
to the maximum level mark, and
then close the coolant reservoir
cap.
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.

If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
6. Install the coolant reservoir cover
by installing the screw.
7. Place the right floorboard mat in
the original position.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-37 for further instructions.
1. Minimum level mark
2. Maximum level mark
3. Coolant reservoir cap
1
2
3

Coolant reservoir capacity (up to
the maximum level mark):
0.32 L (0.34 US qt)
(0.28 Imp.qt)

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CAUTION:

ECA12922

Make sure that each filter ele-
ment is properly seated in its
case.

Always replace both air filter el-
ements at the same time, other-
wise poor engine performance
or damage to the engine may re-
sult.

The engine should never be op-
erated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
To clean the air filter check hoses
1. Check the hose at the bottom of
both air filter cases for accumulat-
ed dirt or water.
Left
Right
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
Cleaning the V-belt case air filter el-
ement
1. Remove cowling E. (See
page 6-6.)
2. Remove panel B. (See page 6-6.)
3. Remove the V-belt air filter case
cover by removing the screws.
4. Remove the V-belt case air filter
element by removing the screws.

1. Air filter check hose
1. Air filter check hose
1
1

1. Screw
2. V-belt air filter case cover
2
11(×5)1

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EAU21400
Adjusting the 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.
EAU33600
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

EWA10500

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

EWA11200
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your vehicle, you should keep
the following precautions in mind.

NEVER OVERLOAD THE VEHI-
CLE! Operation of an overload-
ed vehicle may result in tire Tire air pressure (measured on
cold tires):
0–90 kg (0–198 lb) :
Front:
200 kPa (29 psi) (2.00 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
90–198 kg (198–437 lb) :
Front:
200 kPa (29 psi) (2.00 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
Maximum load*:
198 kg (437 lb)
* Total weight of rider, passenger,
cargo and accessories

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EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
EAU23110
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23170
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart. Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

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CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

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EAU25921
Troubleshooting charts
Starting problems or poor engine
performance
WARNING

EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
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
Open the throttle halfway and operate
the electric starter.

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9 Engine overheating
WARNING

EWA10400

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.