2008 YAMAHA MAJESTY 400 check oil

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 ...................................3-5
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
ABS (for ABS models) ...................3-12
Fuel tank cap .................................3-13
Fuel ................................................3-14
Catalytic converters .......................3-14
Seats .............................................3-15
Adjusting the rider seat ..................3-16
Storage compartments ..................3-17
Adjusting the shock absorber
assemblies .................................3-18
Sidestand .......................................3-19Ignition circuit cut-off system ......... 3-20
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 .......................................... 6-7
Checking the spark plug ................ 6-11
Engine oil and oil filter element ..... 6-13
Final transmission oil ..................... 6-16
Coolant .......................................... 6-17
Air filter elements and check hoses and
V-belt case air filter element ...... 6-19
Checking the throttle cable free
play ............................................ 6-22Valve clearance ............................ 6-22
Tires .............................................. 6-22
Cast wheels .................................. 6-24
Front and rear brake lever free
play ............................................ 6-25
Adjusting the rear brake lock lever
cable .......................................... 6-26
Checking the front and rear brake
pads ........................................... 6-26
Checking the brake fluid level ....... 6-27
Changing the brake fluid ............... 6-28
Checking and lubricating the
cables ........................................ 6-28
Checking and lubricating the throttle
grip and cable ............................ 6-29
Lubricating the front and rear brake
levers ......................................... 6-29
Checking and lubricating the
centerstand and sidestand ........ 6-29
Checking the front fork .................. 6-30
Checking the steering ................... 6-31
Checking the wheel bearings ........ 6-31
Battery ........................................... 6-32
Replacing the fuses ...................... 6-33
Replacing a headlight bulb ........... 6-35
Tail/brake light ............................... 6-36
Replacing a front turn signal light
bulb ............................................ 6-36
Replacing a rear turn signal light
bulb ............................................ 6-37

INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
the fuel reserve tripmeter manually, it
will reset itself automatically and the
display will return to the prior mode af-
ter refueling and traveling 5 km (3 mi).
NOTE:

The display cannot be changed back to
“TRIP F” after pushing the “RESET”
button.
Fuel meter
With the key in the “ON” position, the
fuel meter indicates the amount of fuel
in the fuel tank. The display segments
of the fuel meter disappear towards “E”
(Empty) as the fuel level decreases.
When the fuel level reaches the bottom
segment near “E”, the fuel level warn-
ing indicator and the bottom segment
will flash. Refuel as soon as possible.
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. The
coolant temperature varies with chang-
es in the weather and engine load. If
the top segment and coolant tempera-
ture warning indicator flash, stop thevehicle and let the engine cool. (See
page 6-40.)
CAUTION:

ECA10020
Do not operate the engine if it is
overheated.
Oil change indicator “OIL”
This indicator flashes at the initial 1000
km (600 mi), then at 5000 km (3000 mi)
and every 5000 km (3000 mi) thereafter
to indicate that the engine oil should be
changed.
After changing the engine oil, reset the
oil change indicator. (See page 6-13.)
If the engine oil is changed before the
oil change indicator comes on (i.e. be-
fore the periodic oil change interval hasbeen reached), the indicator must be
reset after the oil change for the next
periodic oil change to be indicated at
the correct time. (See page 6-13.)
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
(12500 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can
be checked according to the following

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15605
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-14
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-13
Final transmission oil

Check vehicle for oil leakage. 6-16
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-17
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-26
Rear brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-26
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-22, 6-29

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

9*
Brake hoses

Check for cracks or damage.
√√√√√

Replace. Every 4 years
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 steer-
ing for roughness.
√√√√√

Lubricate with lith-
ium-soap-based grease.Every 20000 km (12000 mi)
14

*
Chassis fasteners

Make sure that all nuts, bolts
and screws are properly tight-
ened.
√√√√√
15

Front brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
16

Rear brake lever
pivot shaft

Lubricate with silicone grease.
√√√√√
17

Sidestand, center-
stand

Check operation.

Lubricate.
√√√√√
18

*
Sidestand switch

Check operation.
√√√√√√
19

*
Front fork

Check operation and for oil
leakage.
√√√√
20

*
Shock absorber
assemblies

Check operation and shock
absorbers for oil leakage.
√√√√
21

*
Fuel injection

Check engine idle speed.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

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

22

Engine oil

Change. (See pages 3-5 and
6-13.)
√
When the oil change indicator flashes [every 5000 km (3000 mi)]

Check oil level and vehicle for
oil leakage.Every 5000 km (3000 mi)
√
23

Engine oil filter ele-
ment

Replace.
√√√
24

*
Cooling system

Check coolant level and vehi-
cle for coolant leakage.
√√√√√

Change. Every 3 years
25

Final transmission
oil

Check vehicle for oil leakage.
√√ √

Change.
√√√√√√
26

*
V-belt

Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
27

*
Front and rear brake
switches

Check operation.
√√√√√√
28

Moving parts and
cables

Lubricate.
√√√√√
29

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

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

EAU34183
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. Dipstick
3. Maximum level mark
4. Minimum level mark
1
3
4
1
2

1. Engine oil drain bolt
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
2
3
4
5
67
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.
NOTE:

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
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.

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. “CD” specification
2. “ENERGY CONSERVING II”
1
2