2004 YAMAHA MAJESTY 400 wheel
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EAU26941
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
5RU-9-E0_hyoushi2&3 10/23/03 6:34 PM Page 1
Page 6 of 92
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
Page 9 of 92
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:
Page 27 of 92
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
Page 37 of 92
PRE-OPERATION CHECKS
4-3
2
3
45
6
7
8
9
Wheels and tires
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-21, 6-23
Brake levers
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-27
Centerstand, sidestand
Make sure that operation is smooth.
Lubricate pivots if necessary.6-28
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switches
Check operation.
Correct if necessary.—
Sidestand switch
Check operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-17
ITEM CHECKS PAGE
Page 45 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9
10
*
Wheels
Check runout and for damage.
√
√
√
√
11
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
12
*
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
13
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 20000 km
14
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
√
√
√
√
√
15
Sidestand, centerstand
Check operation.
Lubricate.
√
√
√
√
√
16
*
Sidestand switch
Check operation.
√
√
√
√
√
√
17
*
Front fork
Check operation and for oil leakage.
√
√
√
√
18
*
Shock absorber assem-
blies
Check operation and shock absorbers for oil leakage.
√
√
√
√
19
*
Electronic fuel injection
Adjust engine idling speed.
√
√
√
√
√
√
20
Engine oil
Change. (See pages 3-5 and 6-12.)
√
When the oil change indicator flashes (every
5000 km)
Check oil level and vehicle for oil leakage. Every 5000 km
√
21
Engine oil filter element
Replace.
√
√
√
22
*
Cooling system
Check coolant level and vehicle for coolant leakage.
√
√
√
√
√
Change. Every 3 years
23
Final transmission oil
Check vehicle for oil leakage.
√
√
√
Change.
√
√
√
√
√
√
24
*
V-belt
Replace. Every 20000 km
25
*Front and rear brake
switches
Check operation.√ √ √ √ √ √
26
Moving parts and cables
Lubricate.√ √ √ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
Page 57 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
2
3
4
5
67
8
9
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
Page 63 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
2
3
4
5
67
8
9 damage, loss of control, or se-
vere injury. Make sure that the
total weight of rider, passenger,
cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.
Adjust the tire air pressure with
regard to the load.
Check the tire condition and air
pressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This model is equipped with tubeless
tires.
WARNING
EWA10470
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)12
Front tire:
Size:
120/80-14M/C 58S
Manufacturer/model:
IRC/MB67
DUNLOP/D305FL
Rear tire:
Size:
150/70-13M/C 64S
Manufacturer/model:
IRC/MB67
DUNLOP/D305L