2004 YAMAHA MAJESTY 400 turn signal

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
1-2
1
the speed).

Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.

Always signal before turning or
changing lanes. Make sure that
other motorists can see you.

The posture of the operator and
passenger is important for proper
control.

The operator should keep both
hands on the handlebar and
both feet on the footboard during
operation to maintain control of
the scooter.

The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.

Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.

Never ride under the influence of
alcohol or other drugs.

This scooter is designed foron-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from scooter
accidents are the result of head inju-
ries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.

Always wear an approved helmet.

Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision which could delay seeing
a hazard.

The use of a jacket, substantial
shoes, trousers, gloves, etc., is ef-
fective in preventing or reducing
abrasions or lacerations.

Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.

Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-tive clothing that covers your legs,
ankles, and feet.

Passengers should also observe
the above precautions.
Modifications
Modifications made to this scooter not
approved by Yamaha, or the removal of
original equipment, may render the
scooter unsafe for use and may cause
severe personal injury. Modifications
may also make your scooter illegal to
use.
Loading and accessories
Adding accessories or cargo to your
scooter can adversely affect stability
and handling if the weight distribution of
the scooter is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or accesso-
ries to your scooter. Use extra care
when riding a scooter that has added
cargo or accessories. Here are some
general guidelines to follow if loading
cargo or adding accessories to your
scooter:

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.

INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9keys away from the main switch
as they may cause signal inter-

ference.
EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.
NOTE:

Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code
re-registering key (red bow), keep it in a
safe place and only use it for code
re-registering.
EAU34121
ON
All electrical circuits are supplied with
power; the meter lighting, taillight, li-
cense plate light and auxiliary lights
come on, and the engine can be start-ed. The key cannot be removed.
NOTE:

The headlights come on automatically
when the engine is started and stay on
until the key is turned to “OFF” or the
sidestand is moved down.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to
“OFF” while still pushing it.

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

EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU33491
(Parking)
The steering is locked, and the taillights
and auxiliary lights are on. The hazard
light and turn signal lights can be turned
on, but all other electrical systems are
off. The key can be removed.
The steering must be locked before the
key can be turned to “ ”.
CAUTION:

ECA11020
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11001
Indicator and warning lights
EAU11030
Turn signal indicator lights “” and
“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11480
Engine trouble warning light “”
This warning light comes on when an
electrical circuit monitoring the engine
is defective. When this occurs, have a
Yamaha dealer check the self-diagno-
sis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU26871
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
1. Turn signal indicator lights “ ” and “ ”
2. High beam indicator light “ ”
3. Immobilizer system indicator light “ ”
4. Engine trouble warning light “ ”
1234

INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
periodic oil change to be indicated at
the correct time. (See page 6-12.)
The electrical circuit of the indicator can
be checked according to the following
procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Check that the indicator comes on
for a few seconds and then goes
off.
3. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
NOTE:

The oil change indicator may flash
when the engine is revved with the
scooter on the centerstand, but this
does not indicate a malfunction.
V-belt replacement indicator
“V-BELT”
This indicator flashes every 20000 km
(12000 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can
be checked according to the following
procedure.1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
2. If the indicator does not come on,
have a Yamaha dealer check the
electrical circuit.
Self-diagnosis device
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
multi-function display will indicate a
two-digit error code (e.g., 12, 13, 14).
If the multi-function display indicates
such an error code, note the code num-
ber, and then have a Yamaha dealer
check the vehicle.
CAUTION:

ECA11790
If the multi-function display indi-
cates an error code, the vehicle
should be checked as soon as pos-
sible in order to avoid engine dam-
age.
This model is also equipped with a
self-diagnosis device for the immobiliz-er system.
If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code (e.g., 51, 52, 53)
when the key is turned to “ON”.
NOTE:

If the multi-function display indicates er-
ror code 52, this could be caused by
transponder interference. If this error
appears, try the following.
1. Use the code re-registering key to
start the engine.
NOTE:

Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.

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

EAU12343
Handlebar switches
LeftRight
EAU12360
Pass switch “PASS”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “/”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12460
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re-
leased, the switch returns to the center
position. To cancel the turn signallights, push the switch in after it has re-
turned to the center position.
EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12660
Engine stop switch “/”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12720
Start switch “”
With the sidestand up, push this switch
while applying the front or rear brake to
crank the engine with the starter.
CAUTION:

ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU12731
Hazard switch “”
With the key in the “ON” or “ ” posi-
tion, use this switch to turn on the haz-
ard light (simultaneous flashing of all
turn signal lights).
The hazard light is used in case of an
1. Pass switch “PASS”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
1
2
34

1. Engine stop switch “ / ”
2. Hazard switch “ ”
3. Start switch “ ”
1
2
3

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