2004 YAMAHA MAJESTY 400 engine

PERIODIC MAINTENANCE AND MINOR REPAIR
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9
NOTE:

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.
NOTE:

Make sure that the washer is properly
seated.
9. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:

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.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.
NOTE:

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 at
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
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)

1. “OIL CHANGE” button
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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the 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.
EAU20060
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 it up by
riding the scooter for several min-
utes, 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 oil filler cap and drain
bolt to drain the oil from the final
transmission case.5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
1. Final transmission oil filler cap
2. Final transmission oil drain bolt
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m·kgf, 15.9 ft·lbf)
2
1

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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

PERIODIC MAINTENANCE AND MINOR REPAIR
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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)

PERIODIC MAINTENANCE AND MINOR REPAIR
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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)

PERIODIC MAINTENANCE AND MINOR REPAIR
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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.