2011 YAMAHA MAJESTY 400 transmission

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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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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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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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
2
3
4
5
67
8
9
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)
21
34
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
1
2
3
4
5
6
7
8
9tire or wheel.

[EWA11311]

8. Install the final transmission oil fill-
er cap and its new O-ring, and then
tighten the oil filler cap.
9. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU34193
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Pull up the right floorboard mat as
shown.3. Remove the coolant reservoir cov-
er by removing the screw.
4. Check the coolant level in the cool-
ant reservoir.
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt, 0.22 Imp.qt)
1. Right floorboard mat
1. Screw
2. Coolant reservoir cover
1
1
2
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8-1
2
3
4
5
6
7
89

SPECIFICATIONS
EAU2633Z
Dimensions:
Overall length:
2230 mm (87.8 in)
Overall width:
780 mm (30.7 in)
Overall height:
1380 mm (54.3 in)
Seat height:
760 mm (29.9 in)
Wheelbase:
1565 mm (61.6 in)
Ground clearance:
120 mm (4.72 in)
Minimum turning radius:
2600 mm (102.4 in)
Weight:
Curb weight:
YP400 220 kg (485 lb)
YP400A 223 kg (492 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Single cylinder
Displacement:
395 cm
3

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:
Recommended brand:
YAMALUBE
Type:
SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO stan-
dard MA
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:
YAMALUBE 10W-40 or SAE 10W-30 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:
Throttle body:
ID mark:
5RUG 20
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 ratio:
1.000
Final drive:
Gear
Secondary reduction ratio:
6.643 (31/14 x 42/14)
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
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SPECIFICATIONS
8-2
1
2
3
4
5
6
7
8
9

Transmission type:
V-belt automatic
Chassis:
Frame type:
Backbone
Caster angle:
27.00 °
Trail:
100 mm (3.9 in)
Front tire:
Type:
Tubeless
Size:
120/80-14M/C 58S
Manufacturer/model:
IRC/MB67
Manufacturer/model:
DUNLOP/D305FL
Rear tire:
Type:
Tubeless
Size:
150/70-13M/C 64S
Manufacturer/model:
IRC/MB67
Manufacturer/model:
DUNLOP/D305L
Loading:
Maximum load:
YP400 188 kg (414 lb)
YP400A 185 kg (408 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
200 kPa (2.00 kgf/cm
2

, 29 psi)
Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
Loading condition:
YP400 90–188 kg (198–414 lb)
YP400A 90–185 kg (198–408 lb)
Front:
200 kPa (2.00 kgf/cm
2

, 29 psi)
Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
Front wheel:
Wheel type:
Cast wheel
Rim size:
14M/C x MT3.00
Rear wheel:
Wheel type:
Cast wheel
Rim size:
13M/C x MT4.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Left hand operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
120.0 mm (4.72 in)
Rear suspension:
Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
104.0 mm (4.09 in)
Electrical system:
Ignition system:
TCI
Charging system:
AC magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8.0 Ah
Headlight:
Bulb type:
Halogen bulb
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INDEX
A
ABS (for ABS models) ............................. 3-13
ABS warning light (for ABS models) .......... 3-4
Acceleration and deceleration ................... 5-2
Air filter elements and check hoses
and V-belt case air filter element ........... 6-17
Anti-theft alarm (optional) .......................... 3-9
Auxiliary light bulb.................................... 6-35
B
Battery ..................................................... 6-30
Brake fluid, changing ............................... 6-26
Brake fluid level, checking ....................... 6-25
Brake lever, front ..................................... 3-11
Brake lever, rear ...................................... 3-12
Brake levers, lubricating .......................... 6-27
Braking ...................................................... 5-3
C
Cables, checking and lubricating ............. 6-26
Care ........................................................... 7-1
Catalytic converters ................................. 3-16
Centerstand and sidestand, checking
and lubricating ....................................... 6-28
Coolant .................................................... 6-16
Cowlings and panels, removing and
installing .................................................. 6-7
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 ...................... 3-3
F
Final transmission oil ............................... 6-15Front and rear brake lever free play,
checking ................................................ 6-23
Front and rear brake pads, checking....... 6-24
Front fork, checking ................................. 6-28
Front turn signal light ............................... 6-34
Fuel ......................................................... 3-15
Fuel consumption, tips for reducing .......... 5-3
Fuel tank cap ........................................... 3-14
Fuses, replacing ...................................... 6-31
H
Handlebar switches ................................. 3-10
Hazard switch .......................................... 3-11
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 ................... 3-22
Immobilizer system.................................... 3-1
Immobilizer system indicator light ............. 3-4
Indicator and warning lights....................... 3-3
L
License plate light bulb, replacing ........... 6-35
M
Main switch/steering lock .......................... 3-2
Maintenance and lubrication, periodic ....... 6-4
Maintenance, emission control system ..... 6-3
Matte color, caution ................................... 7-1
Model label ................................................ 9-1
Multi-function display ................................. 3-5
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Pass switch ............................................. 3-10
R
Rear brake lock lever .............................. 3-12
Rear brake lock lever cable, adjusting .... 6-24
Rider seat, adjusting ............................... 3-18
S
Safe-riding points ...................................... 1-5
Safety information ..................................... 1-1
Seats ....................................................... 3-17
Shock absorber assemblies,
adjusting ............................................... 3-21
Sidestand ................................................ 3-21
Spark plug, checking............................... 6-10
Specifications ............................................ 8-1
Speedometer ............................................ 3-5
Starting off................................................. 5-2
Starting the engine .................................... 5-1
Start switch ............................................. 3-10
Steering, checking .................................. 6-29
Storage ..................................................... 7-3
Storage compartments............................ 3-19
T
Tachometer ............................................... 3-5
Tail/brake light......................................... 6-33
Throttle grip and cable, checking and
lubricating ............................................. 6-27
Throttle grip free play, checking .............. 6-20
Tires ........................................................ 6-21
Tool kit ...................................................... 6-2
Troubleshooting ...................................... 6-36
Troubleshooting charts ........................... 6-37
Turn signal indicator lights ........................ 3-3
Turn signal light bulb (rear), replacing .... 6-34
Turn signal switch ................................... 3-10
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