2010 YAMAHA MAJESTY 400 torque

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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.

Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU17502
Owner’s tool kit
The owner’s tool kit is located inside the
rear storage compartment. (See
page 3-19.)
Pull up the storage compartment mat,
and then remove the owner’s tool kit.
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
1. Storage compartment mat
2. Owner’s tool kit
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PERIODIC MAINTENANCE AND ADJUSTMENT
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2. Install the screw access cover by
placing it in its original position.
3. Install the grab bar by installing the
collars and grab bar bolts.
4. Install the passenger seat.
5. Install cowlings A and B.
Cowling E
To remove the cowling
1. Pull up the left floorboard mats as
shown.2. Remove the cowling screws.
3. Pull the cowling down slightly, and
then pull it outward as shown.To install the cowling
1. Insert the projections on the cowl-
ing into the slots as shown, and
then install the screws.
2. Place the left floorboard mats in
the original position.

Tightening torque:
Grab bar bolt:
23 Nm (2.3 m·kgf, 16.6 ft·lbf)
1. Left floorboard mat
1. Screw
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1. Cowling E
1. Projection
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PERIODIC MAINTENANCE AND ADJUSTMENT
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3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIP

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
TIP

Make sure the spark plug wire is fas-
tened in the clamp as shown.5. Install the spark plug cover by in-
stalling the screws.
6. Place the storage compartment
mat in the original position.
7. Close the rider seat.
EAU34187
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. 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 it
again to check the oil level.
TIP

The engine oil should be between the
tip of the dipstick and the maximum lev-
el mark.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)
1. Spark plug cap
2. Spark plug wire clamp
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PERIODIC MAINTENANCE AND ADJUSTMENT
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7. Install the compression spring and
oil filter element cover by installing
the bolts, then tightening them to
the specified torque.
TIP

Make sure that the O-rings are properly
seated.
8. Install the engine oil drain bolt and
its new gasket, and then tightenthe bolt to the specified torque.
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIP

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

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.

1. Oil filter element cover
2. O-ring
3. Compression spring
4. Oil filter element
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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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
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PERIODIC MAINTENANCE AND ADJUSTMENT
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3. Release the “OIL CHANGE” but-
ton, and the oil change indicator
will go off.
TIP

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-
cator will come on for 1.4 seconds after
releasing the “OIL CHANGE” button,
otherwise repeat the procedure.
EAU20065
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm up the final
transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the center-
stand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the fi-
nal transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.6. Install the final transmission oil
drain bolt and its new gasket, and
then tighten the bolt to the speci-
fied torque.
7. Refill with the specified amount of
the recommended final transmis-
sion oil.
WARNING! Make sure
that no foreign material enters
the final transmission case.
Make sure that no oil gets on the
1. Final transmission oil filler cap
2. O-ring
3. Final transmission oil drain bolt
4. Gasket
Tightening torque:
Final transmission oil drain bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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9Tire information
This model is equipped with tubeless
tires.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
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 aYamaha dealer, who has the
necessary professional knowl-
edge and experience.
EAU21992
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends, warpage or
damage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.

After repairing or replacing the rear
tire, tighten the valve stem nut and
locknut to the specified torques.
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

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU33453
Front and rear brake lever free
play
Front
Rear
There should be no free play at thebrake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING

EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re-
sult in loss of control and an acci-
dent.
1. Valve stem nut
2. Valve stem locknut
Tightening torques:
Valve stem nut:
2.0 Nm (0.2 m·kgf, 1.4 ft·lbf)
Valve stem locknut:
3.0 Nm (0.3 m·kgf, 2.2 ft·lbf)
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1. Brake lever free play
1. Brake lever free play
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