2006 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 .......................3-4
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Front brake lever ...........................3-10
Rear brake lever ............................3-10
Rear brake lock lever .....................3-10
Fuel tank cap .................................3-11
Fuel ................................................3-12
Catalytic converter .........................3-13
Seats .............................................3-13
Adjusting the rider seat ..................3-14
Storage compartments ..................3-15
Sidestand .......................................3-17
Ignition circuit cut-off system .........3-17
PRE-OPERATION CHECKS
...............4-1Pre-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 ............................. 6-21
Tires .............................................. 6-21
Cast wheels ................................... 6-23Front and rear brake lever free
play ............................................ 6-23
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 ..... 6-33
Replacing a rear turn signal light
bulb ............................................ 6-34
Replacing the license plate light
bulb ............................................ 6-35
Troubleshooting ............................ 6-36
Troubleshooting charts ................. 6-37

SAFETY INFORMATION
1-3
1
When loading within this weight limit,
keep the following in mind:

Cargo and accessory weight
should be kept as low and close to
the scooter as possible. Make sure
to distribute the weight as evenly
as possible on both sides of the
scooter to minimize imbalance or
instability.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.

Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot test
all other accessories that may be avail-
able, you must personally be responsi-
ble for the proper selection, installationand use of non-Yamaha accessories.
Use extreme caution when selecting
and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your scooter. Carefully
inspect the accessory before using
it to make sure that it does not in
any way reduce ground clearance
or cornering clearance, limit sus-
pension travel, steering travel or
control operation, or obscure lights
or reflectors.

Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamiceffects. Wind may attempt to lift
the scooter, or the scooter may
become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

Use caution when adding electri-
cal accessories. If electrical acces-
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.

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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 3-17, 6-28)

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9
rear brake lock lever is applied.


To provide secure locking of the
rear 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.
To 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-

1. Lid
2. Opening lever
2 1

1. Fuel tank cap
1. Match marks
1
1

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
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9
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, sincefuel 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.
1. Fuel tank filler tube
2. Fuel level
21

Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
14.0 L (3.70 US gal) (3.08 Imp.gal)

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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 a
brush, 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 in
contact with strong or abrasive
cleaning products, solvent orthinner, 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
scratched, use a quality plastic
polishing compound after
washing.

SCOOTER CARE AND STORAGE
7-3
1
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what products to use.
EAU36560
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. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and thefuel from deteriorating.
3. 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.
WARNING

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
4. Lubricate all control cables and the

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SPECIFICATIONS
EAU2633E
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:
395.0 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)
Fuel injection:
Manufacturer:
AISAN
Model/quantity:
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