2005 YAMAHA MAJESTY 400 oil filter

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 .....................................3-5
Multi-function display .......................3-5
Anti-theft alarm (optional) ................3-9
Handlebar switches .........................3-9
Front brake lever ...........................3-11
Rear brake lever ............................3-11
Rear brake lock lever .....................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Catalytic converter .........................3-14
Seats .............................................3-14
Adjusting the rider seat ..................3-15
Storage compartments ..................3-16
Sidestand .......................................3-18
Ignition circuit cut-off system .........3-18
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
Checking the throttle cable free
play ............................................ 6-20
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

OPERATION AND IMPORTANT RIDING POINTS
5-4
1
2
3
4
5
6
7
8
9

EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU34320
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
CAUTION:

ECA12930
After 1000 km (600 mi) of operation,be sure to replace the engine oil, fi-
nal transmission oil and the oil filter
element.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
1
2
3
4
5
6
7
8
9

EAU34181
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart and when the oil change in-
dicator comes on.
To check the engine oil level
1. Place the vehicle on the center-
stand.
NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove itagain to check the oil level.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
4. Check the washer for damage and
replace it if necessary.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
1
2
3
1

1. Engine oil drain bolt
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
2
3
4
5
67
8
9
NOTE:

Skip steps 5–7 if the oil filter element is
not being replaced.
5. Remove the oil filter element cover
by removing the bolts.6. Remove and replace the oil filter
element and O-rings.
CAUTION:

ECA12910
When removing the oil filter element
cover, the compression spring will
fall out. Take care not to lose the
compression spring.
7. Install the compression spring and
oil filter element cover by installing
the bolts, then tightening them to
the specified torque.
1. Engine oil drain bolt
2. Washer
2
1

1. Bolt
2. Oil filter element cover
21
(×3)
1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
1
2
3
4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
1
2
3
4
5
6
7
8
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
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-
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 replace-
ment:
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

8-1
2
3
4
5
6
7
89

SPECIFICATIONS
EAU26338
Dimensions:
Overall length:
2230 mm (87.8 in)
Overall width:
780 mm (30.7 in)
Overall height:
1380 mm (54.3 in)
Seat height:
750 mm (29.5 in)
Wheelbase:
1565 mm (61.6 in)
Ground clearance:
120 mm (4.72 in)
Minimum turning radius:
2600 mm (102.4 in)
Weight:
With oil and fuel:
214.0 kg (472 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
394.9 cm
3

(24.10 cu.in)
Bore
×
stroke:
83.0
×
73.0 mm (3.27
×
2.87 in)
Compression ratio:
10.60 :1
Starting system:
Electric starter
Lubrication system:
Wet sump

Engine oil:
Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine 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)
Final transmission oil:
Type:
SAE10W30 type SE motor oil
Quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.32 L (0.34 US qt) (0.28 Imp.qt)
Radiator capacity (including all routes):
1.57 L (1.66 US qt) (1.38 Imp.qt)
Air filter:
Air filter element:
Oil-coated paper element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)
Electronic fuel injection:
Manufacturer:
AISAN
Model:
1100-87C00-A
Spark plug(s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
31/14 (2.214)
Secondary reduction system:
Helical gear
Secondary reduction ratio:
42/16 (2.625)
Transmission type:
V-belt automatic
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40

INDEX
A
Acceleration and deceleration................... 5-2
Air filter elements and check hoses and
V-belt case air filter element ................. 6-18
Anti-theft alarm (optional).......................... 3-9
B
Battery..................................................... 6-30
Brake fluid, changing .............................. 6-26
Brake fluid level, checking ...................... 6-25
Brake lever, front..................................... 3-11
Brake lever, rear ..................................... 3-11
Brake levers, lubricating.......................... 6-27
Braking ...................................................... 5-2
C
Cables, checking and lubricating ............ 6-27
Care .......................................................... 7-1
Catalytic converter .................................. 3-14
Centerstand and sidestand, checking
and lubricating ...................................... 6-28
Coolant.................................................... 6-16
Cowlings and panels, removing and
installing.................................................. 6-6
D
Dimmer switch ........................................ 3-10
E
Engine break-in ......................................... 5-4
Engine oil and oil filter element ............... 6-12
Engine stop switch .................................. 3-10
Engine trouble warning light...................... 3-4
F
Final transmission oil .............................. 6-15
Front and rear brake lever free play........ 6-24
Front and rear brake pads, checking ...... 6-25
Front fork, checking ................................ 6-28Fuel ..........................................................3-13
Fuel consumption, tips for reducing ...........5-3
Fuel tank cap ...........................................3-12
Fuses, replacing ......................................6-31
H
Handlebar switches ...................................3-9
Hazard switch ..........................................3-10
Headlight bulb, replacing .........................6-33
High beam indicator light ...........................3-3
Horn switch ..............................................3-10
I
Identification numbers................................9-1
Ignition circuit cut-off system ...................3-18
Immobilizer system ....................................3-1
Immobilizer system indicator light ..............3-4
Indicator and warning lights .......................3-3
K
Key identification number ..........................9-1
L
License plate light bulb, replacing ...........6-36
M
Main switch/steering lock ...........................3-2
Model label ................................................9-2
Multi-function display .................................3-5
P
Parking.......................................................5-4
Part locations .............................................2-1
Pass switch ..............................................3-10
Periodic maintenance and lubrication
chart ........................................................6-3
Pre-operation check list .............................4-2
R
Rear brake lock lever ...............................3-11
Rear brake lock lever cable, adjusting .....6-24Rider seat, adjusting................................ 3-15
S
Safe-riding points ...................................... 1-4
Safety information ..................................... 1-1
Seats ....................................................... 3-14
Sidestand ................................................ 3-18
Spark plug, checking ............................... 6-10
Specifications ............................................ 8-1
Speedometer ............................................. 3-4
Starting off ................................................. 5-2
Starting the engine .................................... 5-1
Start switch .............................................. 3-10
Steering, checking ................................... 6-29
Storage ...................................................... 7-3
Storage compartments ............................ 3-16
T
Tachometer ............................................... 3-5
Tail/brake light ......................................... 6-33
Throttle cable free play, checking............ 6-20
Throttle grip and cable, checking and
lubricating .............................................. 6-27
Tires ........................................................ 6-21
Tool kit ....................................................... 6-1
Troubleshooting....................................... 6-36
Troubleshooting charts ............................ 6-37
Turn signal indicator lights......................... 3-3
Turn signal light bulb (front) or auxiliary
light bulb, replacing ............................... 6-34
Turn signal light bulb (rear), replacing ..... 6-35
Turn signal switch.................................... 3-10
V
Valve clearance ....................................... 6-21
Vehicle identification number .................... 9-1