2004 YAMAHA MAJESTY 400 fuel cap

TABLE OF CONTENTS
SAFETY INFORMATION

...................1-1
Further safe-riding points .................1-4
DESCRIPTION

...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS

.......................................3-1
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Speedometer ...................................3-4
Tachometer .....................................3-4
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-9
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-11
Fuel tank cap .................................3-11
Fuel ................................................3-12
Catalytic converter .........................3-13
Seats .............................................3-13
Adjusting the rider seat ..................3-15
Storage compartments ..................3-15
Sidestand .......................................3-17
Ignition circuit cut-off system .........3-17
PRE-OPERATION CHECKS

............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-2
Tips for reducing fuel
consumption .................................. 5-3
Engine break-in ............................... 5-4
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and
lubrication chart ............................. 6-3
Removing and installing cowlings
and panels .................................... 6-6
Checking the spark plug ................ 6-10
Engine oil and oil filter element ..... 6-12
Final transmission oil ..................... 6-15
Coolant .......................................... 6-16
Air filter elements and check hoses
and V-belt case air filter
element ....................................... 6-18
Adjusting the throttle cable free
play ............................................. 6-20
Adjusting the valve clearance ....... 6-21Tires .............................................. 6-21
Cast wheels .................................. 6-23
Front and rear brake lever free
play ............................................. 6-24
Adjusting the rear brake lock lever
cable ........................................... 6-24
Checking the front and rear brake
pads ............................................ 6-25
Checking the brake fluid level ....... 6-25
Changing the brake fluid ............... 6-26
Checking and lubricating the
cables ......................................... 6-27
Checking and lubricating the
throttle grip and cable ................. 6-27
Lubricating the front and rear
brake levers ................................ 6-27
Checking and lubricating the
centerstand and sidestand ......... 6-28
Checking the front fork .................. 6-28
Checking the steering ................... 6-29
Checking the wheel bearings ........ 6-30
Battery ........................................... 6-30
Replacing the fuses ...................... 6-31
Replacing a headlight bulb ........... 6-33
Tail/brake light ............................... 6-33
Replacing a front turn signal light
bulb or an auxiliary light bulb ...... 6-34
Replacing a rear turn signal light
bulb ............................................. 6-35
Replacing the license plate light
bulb ............................................. 6-36

SAFETY INFORMATION
1-4
1
sories exceed the capacity of the
scooter’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

Always turn the engine off when
refueling.

Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.

Never refuel while smoking or in
the vicinity of an open flame.

Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
scooter in an area that has ade-
quate ventilation.

Always turn the engine off before
leaving the scooter unattended
and remove the key from the mainswitch. When parking the scooter,
note the following:

The engine and exhaust system
may be hot, therefore, park the
scooter in a place where pedes-
trians or children are not likely to
touch these hot areas.

Do not park the scooter on a
slope or soft ground, otherwise it
may fall over.

Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
EAU10370
Further safe-riding points

Be sure to signal clearly when
making turns.

Braking can be extremely difficult
on a wet road. Avoid hard braking,
because the scooter could slide.
Apply the brakes slowly when
stopping on a wet surface.

Slow down as you approach a cor-
ner or turn. Once you have com-
pleted a turn, accelerate slowly.

Be careful when passing parked
cars. A driver might not see you
and open a door in your path.

Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers be-
come extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter up-
right, otherwise it could slide out
from under you.

The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.

2-1
1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU10410
Left view
9 1
2
3
5
67
8
4
10
11

1. Headlight (page 6-33)
2. Fuel tank cap (page 3-11)
3. Rear storage compartment (page 3-15)
4. V-belt case air filter element (page 6-18)
5. Owner’s tool kit (page 6-1)
6. Fuses (page 6-31)
7. Battery (page 6-30)
8. Air filter element (left) (page 6-18)9. Engine oil filter element (page 6-12)
10. Centerstand (page 6-28)
11. Sidestand (page 6-28)

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9

EAU12962
Rear brake lock lever
This vehicle is equipped with a rear
brake lock lever to prevent the rear
wheel from moving while stopped at
traffic signals, railroad crossings, etc.
To lock the rear wheel
Push the rear brake lock lever to the left
until it snaps into place.
To unlock the rear wheel
Push the rear brake lock lever back to
the original position.
NOTE:


Be sure to check that the rear
wheel does not move when the
rear brake lock lever is applied.

To provide secure locking of therear wheel, apply the rear brake le-
ver first before moving the rear
brake lock lever to the left.
WARNING

EWA12361
Never move the rear brake lock lever
to the left while the vehicle is mov-
ing, otherwise loss of control or an
accident may result. Make sure that
the vehicle is stopped before mov-
ing the rear brake lock lever to the
left.
EAU13161
Fuel tank cap
To open the fuel tank cap
1. Open the lid by sliding the lever
forward, and then pull the lever up.
2. Insert the key into the lock and turn
it clockwise. The lock will be re-
leased and the fuel tank cap can
be removed.
1. Rear brake lock lever
1

1. Lid
2. Opening lever
2 1

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9To install the fuel tank cap
1. Align the match marks, insert the
fuel tank cap into the tank opening,
and then push down on the cap.
2. Turn the key counterclockwise to
the original position, and then re-move it.
3. Close the lid.
WARNING

EWA11120
Be sure that the fuel tank cap is
properly installed and locked before
riding the scooter.
EAU13210
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING

EWA10880

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.

Avoid spilling fuel on the hot en-
gine.
CAUTION:

ECA10070
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
1. Fuel tank cap
1. Match marks
1
1

1. Fuel tank filler tube
2. Fuel level
21

INSTRUMENT AND CONTROL FUNCTIONS
3-13
2
34
5
6
7
8
9 fuel may deteriorate painted surfac-

es or plastic parts.
EAU33520
CAUTION:

ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13440
Catalytic converter
This vehicle is equipped with a catalytic
converter in the muffler.
WARNING

EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-
ing any maintenance work.
CAUTION:

ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.

Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.

Do not allow the engine to idle
too long.
EAU34140
Seats
Rider seat
To open the rider seat
1. Place the scooter on the center-
stand.
2. Insert the key into the main switch,
and then turn it counterclockwise. Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
14.0 L (3.70 US gal)
(3.08 Imp.gal)

1. Rider seat
2. Passenger seat
2 1

7-1
1
2
3
4
5
6
7
8
9

SCOOTER CARE AND STORAGE
EAU26090
Care
While the open design of a scooter re-
veals the attractiveness of the technol-
ogy, it also makes it more vulnerable.
Rust and corrosion can develop even if
high-quality components are used. A
rusty exhaust pipe may go unnoticed
on a car, however, it detracts from the
overall appearance of a scooter. Fre-
quent and proper care does not only
comply with the terms of the warranty,
but it will also keep your scooter looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and abrush, but never apply such prod-
ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:

ECA10780

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been incontact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.

Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is

SCOOTER CARE AND STORAGE
7-3
1
2
3
4
5
6
7
8
9treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:

Consult a Yamaha dealer for advice on
what products to use.
EAU26300
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
CAUTION:

ECA10820

Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.

To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into thefuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.