Market Position:
The Yamaha YP400 Majesty was a popular maxi-scooter in its segment, known for its comfort, performance, and touring capabilities. This manual serves owners and independent repair shops looking for authoritative repair information.
Key Features Of Manual:
Most complete Service Repair Manual for the 2004 Yamaha YP400 Majesty. Provides comprehensive technical data, detailed diagrams, a complete list of parts, and step-by-step repair instructions, making it ideal for DIY enthusiasts and professional mechanics alike.
Benefit To Owner:
Empowers owners to perform their own maintenance and repairs, saving money on labor costs and increasing understanding of their vehicle's mechanics.
Competitive Analysis Notes:
Competed with other European and Japanese maxi-scooters of similar displacement, offering a balance of performance, comfort, and practicality for urban commuting and longer journeys.
Systems Covered:
General Information, Specifications, Maintenance, Gearbox & Clutch, Engine Removal and Installation, Engine Fuel System, Engine Lubrication and Cooling, Engine Combustion System, Lubrication System, Cylinder Head/Valves, Alternator/Starter Clutch, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer, Transmission System, Front Wheel and Steering System, Rear Wheel System, Fenders and Exhaust Pipe, Periodic checks & Adjustments, Chassis, Cooling system, Fuel injection system, Braking System, Suspension, Electrical System, Body & Fixtures, Frame/Body Panels/Exhaust System, Wheels & Tyres, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Technical Information & Specifications, Troubleshooting
Electrical System Details:
Covers battery, charging system (alternator, regulator/rectifier), starter motor, ignition system components, lighting circuits, instruments, and switches, with detailed wiring diagrams.
Chassis Systems:
Detailed coverage of front fork (telescopic), rear suspension (swingarm, shock absorbers), steering system, front and rear wheel servicing, tire inspection and replacement, and brake system maintenance (disc brakes front and rear).
Body And Fixtures:
Includes procedures for removing and installing body panels, fairings, seats, storage compartments, and other external fixtures.
Braking System:
Covers front and rear hydraulic disc brakes, including caliper servicing, pad replacement, fluid bleeding, and master cylinder maintenance.
Procedures Included:
Routine maintenance, component inspection, repair and replacement procedures, diagnostic troubleshooting, disassembly and reassembly of major systems, electrical system diagnosis and repair, chassis and suspension adjustments, brake system servicing, fuel system maintenance and repair, engine tune-up and overhaul.
Procedures Included Specific:
Detailed procedures for engine disassembly (cylinder head, piston, crankshaft, transmission), clutch service, CVT maintenance, fuel injector cleaning, ignition system testing, electrical component diagnosis using wiring diagrams, brake caliper servicing, suspension linkage lubrication, and body panel removal/installation.
Troubleshooting Methodology:
Structured troubleshooting based on symptoms, guiding technicians through a logical diagnostic process with checks for electrical circuits, mechanical components, and fuel delivery issues.
Calibration Procedures:
Includes calibration procedures for systems like the throttle body and potentially ECU reset procedures where applicable.
Technical Depth:
Comprehensive, covering everything from basic checks and adjustments to complete engine rebuilds and electrical system diagnostics. Includes detailed diagrams, technical data, and part listings.
Diagnostic Procedures:
Includes comprehensive troubleshooting guides for common and uncommon issues, utilizing diagnostic flowcharts and electrical symptom analysis.
Rebuild Procedures:
Detailed procedures for complete engine and transmission rebuilds, including torque specifications for all fasteners, bearing clearances, and gasket replacement instructions.
Specification Tables:
Extensive tables of technical specifications, including torque values, clearances, fluid capacities, electrical resistance values, and measurement tolerances.
Engine Type:
Four-stroke, liquid-cooled, SOHC, 4-valve
Displacement:
395 cc (24.1 cu. in.)
Bore X Stroke:
83.0 mm x 73.0 mm (3.27 in x 2.87 in)
Horsepower:
Manufacturer-specified output, typically around 28-30 PS (27-30 hp) at the crankshaft.
Torque:
Manufacturer-specified torque, typically around 35-38 Nm (26-28 lb-ft).
Fuel System:
Electronic Fuel Injection (EFI) with Throttle Position Sensor (TPS) and Idle Air Control (IAC) valve.
Fuel Type:
Unleaded gasoline
Fuel Injection Components:
ECU (Engine Control Unit), fuel pump, fuel injectors, throttle body assembly, throttle position sensor (TPS), intake air pressure sensor, intake air temperature sensor, oxygen sensor.
Lubrication System:
Wet sump with trochoid pump.
Cooling System:
Forced liquid cooling with fan.
Cooling System Components:
Radiator, cooling fan, thermostat, water pump, coolant hoses, expansion tank, temperature sensor.
Crankshaft Transmission Balancer
Engine Layout:
Single-cylinder, forward-inclined.
Ignition Timing:
Electronically controlled by ECU based on engine speed and load.
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Spark Plug Replacement:
Refer to manual for specific mileage/time interval, typically around 10,000-20,000 km.
Air Filter Cleaning Replacement:
Inspect every 5,000 km, clean/replace as needed based on operating conditions.
Drive Belt Inspection:
Inspect every 10,000 km (6,000 miles) for wear, cracks, and proper tension. Replace as per wear indicators or if any damage is found.
Engine Oil Type:
Yamalube 4 (or API SG, JASO MA certified 10W-40 viscosity)
Engine Oil Capacity:
Approximately 1.8 L (1.9 US qt) with oil filter change.
Coolant Type:
Permanent type antifreeze coolant with distilled water (50:50 ratio)
Brake Fluid Type:
DOT 4 (or specified equivalent)
Gear Oil Type:
Yamaha Genuine Gear Oil 10W-30 (or equivalent API GL-4, SAE 80)
Common Issues:
Potential for CVT belt wear over high mileage, throttle body cleaning may be required for optimal performance, check for coolant leaks at hose connections.
Common Maintenance Tasks:
Regular checks of coolant level, brake fluid level, tire pressure, and drive belt condition. Periodic cleaning of fuel injectors and throttle body is recommended for optimal engine running.
Potential Issues Documentation:
The manual details how to diagnose and rectify common issues such as starting problems, engine misfires, braking system anomalies, and electrical circuit faults.
Gear Oil Capacity:
Approximately 0.20 L (0.21 US qt)
