2011 YAMAHA MAJESTY 400 maintenance

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Further safe-riding points .................1-5
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 .......................3-10
Front brake lever ...........................3-11
Rear brake lever ............................3-12
Rear brake lock lever .....................3-12
ABS (for ABS models) ...................3-13
Fuel tank cap .................................3-14
Fuel ................................................3-15
Catalytic converters .......................3-16
Seats .............................................3-17
Adjusting the rider seat ..................3-18
Storage compartments ..................3-19
Adjusting the shock absorber
assemblies .................................3-21
Sidestand .......................................3-21Ignition circuit cut-off system ......... 3-22
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-3
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-4
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT
.................................... 6-1
Owner’s tool kit ................................ 6-2
Periodic maintenance chart for
the emission control system ........ 6-3
General maintenance and
lubrication chart ........................... 6-4
Removing and installing
cowlings and panels .................... 6-7
Checking the spark plug ................ 6-10
Engine oil and oil filter element ..... 6-12
Final transmission oil ..................... 6-15
Coolant .......................................... 6-16Air filter elements and check
hoses and V-belt case air
filter element .............................. 6-17
Checking the throttle grip free
play ............................................ 6-20
Valve clearance ............................ 6-20
Tires .............................................. 6-21
Cast wheels .................................. 6-22
Checking the front and rear
brake lever free play .................. 6-23
Adjusting the rear brake lock
lever cable ................................. 6-24
Checking the front and rear
brake pads ................................. 6-24
Checking the brake fluid level ....... 6-25
Changing the brake fluid ............... 6-26
Checking and lubricating the
cables ........................................ 6-26
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 ........ 6-29
Battery ........................................... 6-30
Replacing the fuses ...................... 6-31
Replacing a headlight bulb ........... 6-33
Tail/brake light ............................... 6-33
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
2
34
5
6
7
8
9 your eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change

your clothes.
EAU33520
NOTICE

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 lifeand reduce maintenance costs.
EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING

EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:

Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.

Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.

Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.

Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE

ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
14.0 L (3.70 US gal, 3.08 Imp.gal)
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4-1
2
3
45
6
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel
•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-15
Engine oil
•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-12
Final transmission oil
•Check vehicle for oil leakage. 6-15
Coolant
•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-16
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.6-23, 6-24, 6-25
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6-1
2
3
4
5
67
8
9

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17243
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 charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING

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

EWA15121
Turn off the engine when perform-
ing 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.
WARNING

EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17302
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
1
2
3
4
5
6
7
8
9

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.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Storage compartment mat
2. Owner’s tool kit
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
2
3
4
5
67
8
9

EAU46861
TIP


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
EAU46910
Periodic maintenance chart for the emission control system
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)
1*
Fuel line
•Check fuel hoses for cracks or
damage.
√√√√√
2
Spark plug
•Check condition.
•Clean and regap.
√√
•Replace.
√√
3*
Valves
•Check valve clearance.
•Adjust.Every 40000 km (24000 mi)
4*
Fuel injection
•Check engine idle speed.
√√√√√√
5*
Air induction
system
•Check the air cut-off valve, reed
valve, and hose for damage.
•Replace any damaged parts if
necessary.
√√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
1
2
3
4
5
6
7
8
9

EAU1770C
General maintenance and lubrication chart
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)
1
Air filter elements
•Replace.
√√
2
V-belt case air filter
element
•Clean.
√√√√
3*
Front brake
•Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
•Replace brake pads. Whenever worn to the limit
4*
Rear brake
•Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
•Replace brake pads. Whenever worn to the limit
5*
Brake hoses
•Check for cracks or damage.
•Check for correct routing and
clamping.
√√√√√
•Replace. Every 4 years
6
Rear brake lock
•Check operation.
•Adjust.
√√√√√√
7*
Wheels
•Check runout and for damage.
√√√√
8*
Tires
•Check tread depth and for
damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.
√√√√√
9*
Wheel bearings
•Check bearing for looseness or
damage.
√√√√
10 *
Steering bearings
•Check bearing play and steering
for roughness.
√√√√√
•Lubricate with
lithium-soap-based grease.Every 20000 km (12000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
2
3
4
5
67
8
9

11 *
Chassis fasteners
•Make sure that all nuts, bolts
and screws are properly
tightened.
√√√√√
12
Front brake lever
pivot shaft
•Lubricate with silicone grease.
√√√√√
13
Rear brake lever
pivot shaft
•Lubricate with silicone grease.
√√√√√
14
Sidestand,
centerstand
•Check operation.
•Lubricate with
lithium-soap-based grease.
√√√√√
15 *
Sidestand switch
•Check operation.
√√√√√√
16 *
Front fork
•Check operation and for oil
leakage.
√√√√
17 *
Shock absorber
assemblies
•Check operation and shock
absorbers for oil leakage.
√√√√
18
Engine oil
•Change. (See pages 3-5 and
6-12.)
√
When the oil change indicator flashes
•Check oil level and vehicle for oil
leakage.Every 5000 km (3000 mi)
√
19
Engine oil filter
element
•Replace.
√√√
20 *
Cooling system
•Check coolant level and vehicle
for coolant leakage.
√√√√√
•Change. Every 3 years
21
Final transmission
oil
•Check vehicle for oil leakage.
√√ √
•Change.
√√√√√√
22 *
V-belt
•Replace. When the V-belt replacement indicator flashes [every 20000 km (12000 mi)]
23 *
Front and rear
brake switches
•Check operation.
√√√√√√
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)
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