2005–2007 Yamaha Majesty YP400T Service Manual + YP400W Owner’s Manual (P/N LIT-11616-18-38, LIT-11626-20-31)

This Yamaha Majesty set combines the YP400T Service Manual, P/N LIT-11616-18-38 (first edition, June 2004), and the YP400W Owner’s Manual, P/N LIT-11626-20-31 (first edition, April 2006). Service coverage identifies model codes 5RU4 (USA) and 5RUC (Canada); the companion publication covers YP400W operation and minor maintenance.

The two English PDFs form a 491-page set with searchable main text and embedded bookmarks. Some label and warranty text in the owner’s manual is not searchable.

• Engine repair: Engine removal, camshaft timing, cylinder-head and valve work, piston inspection, crankshaft and balancer service, oil-pump repair, and internal transmission checks.

• CVT and clutch: Primary and secondary sheave removal, sheave-weight and clutch-shoe inspection, controlled spring disassembly, reassembly, and V-belt installation.

• Brakes and chassis: Wheel and brake-disc inspection, static balancing, master-cylinder and caliper repair, hydraulic bleeding, fork overhaul, steering-head service, and swingarm inspection.

• Cooling system: Radiator pressure tests, thermostat checks, water-pump service, oil-cooler inspection, coolant replacement, and cooling-system bleeding.

• Fuel injection: ECU self-diagnosis, fail-safe tables, meter-based diagnostic mode, fault-code troubleshooting, fuel-pressure tests, sensor checks, and actuator tests.

• Electrical systems: Ignition, starting, charging, lighting, signaling, and cooling-circuit diagnosis, supported by system diagrams and the complete color-coded YP400T wiring diagram.

Yamaha wrote the service manual primarily for its dealers and qualified mechanics; the owner’s manual supports basic checks and minor maintenance for owners with the necessary tools and experience.

Engine Repair and Scheduled Service

Access procedures cover the seats, storage box, cowlings, footrest boards, front cowling, and air-filter cases. Scheduled service addresses valve-clearance and exhaust-gas-volume adjustment, idle-speed checks, throttle free play, spark plugs, ignition timing, compression testing, engine and final-transmission oil, and air filters.

Internal engine work: The fuel-injected DOHC single receives detailed treatment of decompression components, cylinder-head inspection, valve guides and seats, piston rings and pins, and crankshaft and connecting-rod measurements. Balancer-shaft installation, crankcase bearing selection, and oil-pump inspection extend the coverage through bottom-end repair.

The camshaft chapter warns that crankshaft movement during installation can upset valve timing, while uneven cap tightening can damage the cylinder head, caps, and camshafts.

CVT, Starter Clutch and Workshop References

Belt-drive instructions address grease contamination of the V-belt and secondary sheave assembly, along with the spring-loaded clutch’s disassembly and assembly tooling. Starter-clutch testing and generator service cover the rotor and stator, with holding-tool and puller references.

Special tools: The catalog pairs Yamaha tool numbers with their 90890-series counterparts. Examples include the YM-04134 sheave spring compressor and YM-04135 fixed block, YU-03153 fuel-pressure gauge and YM-03181 adapter, and YM-04146 plane-bearing installer/remover.

These references help a shop check its equipment before undertaking CVT, fuel-system, fork, valve-train, water-pump, or crankcase repair. Exploded views and job charts identify seals, retainers, replacement parts, and lubrication requirements; torque tables, capacities, clearances, wear limits, and electrical test specifications accompany the relevant work.

Brake, Suspension and Cooling Service

Chassis procedures include rear brake lock lever cable adjustment, brake-pad and hose checks, handlebar service, steering-head adjustment, and rear shock absorber removal and inspection. Fork instructions warn that excessive separation force can damage seals and bushings, while bottoming the inner tube can damage the oil-flow stopper.

Cooling-system drawings show hose and pipe routing. Radiator-cap opening-pressure checks and system leak tests accompany thermostat testing, water-pump seal installation, and oil-cooler pipe and cover inspection.

Fuel-Injection Diagnosis and Emissions Equipment

The FI chapter follows the ECU, injector, and fuel pump through self-diagnosis and fault-specific troubleshooting. Tests cover the throttle-position, intake-air-pressure, intake-air-temperature, coolant-temperature, and crankshaft-position sensors, plus the lean-angle cut-off switch and ISC valve.

Diagnostic tables connect fault codes with sensor readings, actuator checks, and reinstatement methods. This helps a technician distinguish electrical or sensor faults from problems that require internal engine investigation.

Fuel-hose and pump removal, injector inspection, throttle-body checks, TPS testing, and ISC operation are documented. Emissions coverage adds air-induction diagrams, air cut-off and reed-valve checks, and canister and rollover-valve hose arrangements.

Electrical Repair and Circuit Diagrams

Connector inspection, switch-continuity tests, bulb and socket checks, and starter-motor repair support circuit troubleshooting. Maintenance instructions also cover battery charging, fuse diagnosis, bulb replacement, and headlight aiming.

Diagram examples include fuel-injection wiring, the starting circuit cut-off system, and charging-system circuits. Signaling- and cooling-system circuit diagrams supplement the full YP400T wiring drawing, whose component key also identifies optional grip-warmer equipment.

YP400W Owner’s Manual Coverage

The companion book covers controls, pre-operation checks, starting and braking, break-in, maintenance charts, service access, care, storage, specifications, and consumer information. Instrument guidance explains the tachometer, multifunction display, fuel and coolant displays, oil and V-belt indicators, clock, ambient-temperature display, and two-digit self-diagnosis codes.

Its troubleshooting charts address fuel, compression, ignition, battery condition, and overheating.

Scope: The YP400W publication is an owner’s manual rather than a service supplement. Internal repair procedures belong to the YP400T publication, so the model label and applicable specifications matter when selecting parts or procedures.

Fuel-system, brake-fluid, battery, and cooling-system work involves fire, pressure, chemical, and electrical hazards. The procedures call for suitable tools, ventilation, and protective equipment.

File Format, Navigation and Readability

• Service manual: 389 pages, including front and rear covers, two blank pages, a wiring-diagram component key, and the wide-format color wiring diagram.
• Owner’s manual: 102 pages, including covers and the warning page, two limited-warranty pages, two Yamaha Extended Service pages, and a two-page index.

All of these pages are already included in the 491-page total.

Navigation: The service PDF has 339 bookmarks. Chapter entries lead to the chapter contents, with nested entries linking to individual procedures. The owner’s PDF has 36 bookmarks for chapters and selected subsections.

Text and diagrams: The service text is searchable. The owner’s manual has searchable main text, but some warning-label text and the body text on its two limited-warranty pages are outside the text layer. Small component identifiers, connector details, and wire codes in the fuel-injection and signaling diagrams, and in the final color diagram, are legible when enlarged.