Yamaha YP400T Manual de usuario

LIT-11616-18-38 5RU-28197-10

YP400T

SERVICE MANUAL

EAS00001

YP400T

SERVICE MANUAL

First edition, June 2004

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-18-38

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. If there is any question about a service procedure, it is imperative

that you contact a Yamaha dealer for any service information changes that apply to this model. This

policy is intended to provide the customer with the most satisfaction from his vehicle and to conform

to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

NOTE:

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the scooter operator, a bystander or a person checking or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid damage

to the scooter.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section

title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS00008

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 0to Gindicate the following.

0Serviceable with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data

Symbols Hto Min the exploded diagrams

indicate the types of lubricants and lubrication

points.

HEngine oil

IGear oil

JMolybdenum-disulfide oil

KWheel-bearing grease

LLithium-soap-based grease

MMolybdenum-disulfide grease

Symbols Nto Oin the exploded diagrams

indicate the following.

NApply locking agent (LOCTITE®)

OReplace the part

EFG

HIJ

KLM

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

FI –+

ELEC

TRBL

SHTG

EGM

BLS M

New

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

COOLING SYSTEM COOL 6

FUEL INJECTION SYSTEM FI 7

ELECTRICAL SYSTEM ELEC 8

TROUBLESHOOTING TRBL

SHTG 9

–+

CONTENTS

CHAPTER 1

GENERAL INFORMATION

SCOOTER IDENTIFICATION..........................................................................1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-2

OUTLINE OF THE FI SYSTEM.................................................................1-2

FI SYSTEM................................................................................................1-3

INSTRUMENT FUNCTIONS .....................................................................1-4

IMPORTANT INFORMATION .......................................................................1-10

PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-10

REPLACEMENT PARTS.........................................................................1-10

GASKETS, OIL SEALS AND O-RINGS ..................................................1-10

LOCK WASHERS/PLATES AND COTTER PINS ...................................1-11

BEARINGS AND OIL SEALS ..................................................................1-11

CIRCLIPS ................................................................................................1-11

CHECKING THE CONNECTIONS ................................................................1-12

SPECIAL TOOLS ..........................................................................................1-13

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................2-1

ENGINE SPECIFICATIONS ...........................................................................2-2

CHASSIS SPECIFICATIONS ........................................................................2-10

ELECTRICAL SPECIFICATIONS .................................................................2-14

CONVERSION TABLE ..................................................................................2-17

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-17

TIGHTENING TORQUES ..............................................................................2-18

ENGINE TIGHTENING TORQUES.........................................................2-18

CHASSIS TIGHTENING TORQUES.......................................................2-21

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ................2-23

CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES .............2-25

COOLING SYSTEM DIAGRAMS ..................................................................2-26

CABLE ROUTING .........................................................................................2-28

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION..............................................................................................3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION

CONTROL SYSTEM........................................................................................3-1

GENERAL MAINTENANCE AND LUBRICATION CHART............................3-2

COWLING AND COVERS...............................................................................3-4

PASSENGER SEAT AND SIDE COVERS................................................3-4

RIDER SEAT AND STORAGE BOX .........................................................3-5

SIDE COVER MOULDINGS AND FOOTREST BOARDS ........................3-7

FRONT COWLING ....................................................................................3-8

AIR FILTER CASES ......................................................................................3-10

ENGINE .........................................................................................................3-11

ADJUSTING THE VALVE CLEARANCE ................................................3-11

ADJUSTING THE EXHAUST GAS VOLUME .........................................3-16

CHECKING THE ENGINE IDLING SPEED ............................................3-17

ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-18

CHECKING THE SPARK PLUG .............................................................3-18

CHECKING THE IGNITION TIMING.......................................................3-20

MEASURING THE COMPRESSION PRESSURE.................................. 3-21

CHECKING THE ENGINE OIL LEVEL....................................................3-23

CHANGING THE ENGINE OIL ...............................................................3-24

CHANGING THE TRANSMISSION OIL..................................................3-27

REPLACING THE AIR FILTER ELEMENTS...........................................3-28

CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-29

CHECKING THE THROTTLE BODY JOINT AND

INTAKE MANIFOLD ...............................................................................3-30

CHECKING THE FUEL HOSE ................................................................3-30

CHECKING THE BREATHER HOSES ...................................................3-31

CHECKING THE EXHAUST SYSTEM....................................................3-32

CHECKING THE COOLANT LEVEL.......................................................3-32

CHECKING THE COOLING SYSTEM ....................................................3-33

CHANGING THE COOLANT...................................................................3-34

CHASSIS .......................................................................................................3-37

ADJUSTING THE REAR BRAKE LOCK LEVER CABLE .......................3-37

CHECKING THE BRAKE FLUID LEVEL.................................................3-38

CHECKING THE FRONT AND REAR BRAKE PADS ............................3-39

CHECKING THE FRONT AND REAR BRAKE HOSES..........................3-39

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-40

CHECKING AND ADJUSTING THE STEERING HEAD .........................3-41

CHECKING THE FRONT FORK .............................................................3-43

CHECKING THE TIRES..........................................................................3-44

CHECKING THE WHEELS .....................................................................3-47

CHECKING AND LUBRICATING THE CABLES ....................................3-47

LUBRICATING THE LEVERS .................................................................3-48

LUBRICATING THE SIDESTAND...........................................................3-48

LUBRICATING THE CENTERSTAND ....................................................3-48

ELECTRICAL SYSTEM.................................................................................3-49

CHECKING AND CHARGING THE BATTERY.......................................3-49

CHECKING THE FUSES ........................................................................3-54

REPLACING THE HEADLIGHT BULBS .................................................3-56

ADJUSTING THE HEADLIGHT BEAMS................................................. 3-58

CHAPTER 4

CHASSIS

FRONT WHEEL AND BRAKE DISC...............................................................4-1

REMOVING THE FRONT WHEEL............................................................4-3

CHECKING THE FRONT WHEEL ............................................................4-3

CHECKING THE BRAKE DISCS ..............................................................4-4

INSTALLING THE FRONT WHEEL ..........................................................4-6

ADJUSTING THE FRONT WHEEL STATIC BALANCE ...........................4-7

REAR WHEEL AND BRAKE DISC.................................................................4-9

REMOVING THE REAR WHEEL ............................................................4-10

CHECKING THE REAR WHEEL.............................................................4-10

ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-10

FRONT AND REAR BRAKES.......................................................................4-11

FRONT BRAKE PADS ............................................................................4-11

REAR BRAKE PADS...............................................................................4-12

REPLACING THE FRONT BRAKE PADS ..............................................4-13

REPLACING THE REAR BRAKE PADS.................................................4-15

FRONT BRAKE MASTER CYLINDER....................................................4-18

REAR BRAKE MASTER CYLINDER ......................................................4-21

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER .............4-24

DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................4-24

CHECKING THE FRONT AND REAR BRAKE

MASTER CYLINDERS ...........................................................................4-25

ASSEMBLING AND INSTALLING THE FRONT BRAKE

MASTER CYLINDER .............................................................................4-26

ASSEMBLING AND INSTALLING THE REAR BRAKE

MASTER CYLINDER .............................................................................4-28

FRONT BRAKE CALIPER.......................................................................4-31

REAR BRAKE CALIPER .........................................................................4-33

DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-36

DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-36

CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................4-37

ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER .......4-39

ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER..........4-41

FRONT FORK................................................................................................4-44

REMOVING THE FRONT FORK LEGS..................................................4-48

DISASSEMBLING THE FRONT FORK LEGS ........................................4-48

CHECKING THE FRONT FORK LEGS ..................................................4-50

ASSEMBLING THE FRONT FORK LEGS ..............................................4-50

INSTALLING THE FRONT FORK LEGS ................................................4-53

HANDLEBAR ................................................................................................4-54

REMOVING THE HANDLEBAR..............................................................4-56

CHECKING THE HANDLEBAR ..............................................................4-56

INSTALLING THE HANDLEBAR ............................................................4-56

Otros manuales para YP400T

Tabla de contenidos

Otros manuales de Motocicleta de Yamaha

Yamaha

Yamaha SR125'99 3MW-AE3 Manual de usuario

Yamaha

Yamaha 2004 XJR1300 Instrucciones de funcionamiento e instalación

Yamaha

Yamaha FJR1300AS Manual de usuario

Yamaha

Yamaha 2007 V Star XVS650W Manual de usuario

Yamaha

Yamaha TDM850 Manual de usuario

Yamaha

Yamaha WOLUERINE RMAX Manual de usuario

Yamaha

Yamaha Super Tenere XTZ1200Z Manual de usuario

Yamaha

Yamaha DragStar XVS1100 Manual de usuario

Yamaha

Yamaha FZ6-SS Manual de usuario

Yamaha

Yamaha YZF-R6R Manual de usuario

Yamaha

Yamaha V-star XVS650R Manual de usuario

Yamaha

Yamaha PW80(W) Manual de usuario

Yamaha

Yamaha 2013 FJR1300AS Manual de usuario

Yamaha

Yamaha X MAX CZD300-A Manual de usuario

Yamaha

Yamaha MIO AL115S 2010 Manual de usuario

Yamaha

Yamaha TT-R125E(R) Guía de aplicación

Yamaha

Yamaha XJ600SF Manual de usuario

Yamaha

Yamaha Super Tenere ABS XT1200Z 2019 Manual de usuario

Yamaha

Yamaha 2006 YZFR6V Manual de usuario

Yamaha

Yamaha YX600S Manual de usuario

Yamaha

Yamaha '09 YZF-R1 Manual

Yamaha

Yamaha 2001 YZ426F/LC Guía de aplicación

Yamaha

Yamaha FJR1300AE 2020 Manual de usuario

Yamaha

Yamaha FJR1300N Manual de usuario

Manuales populares de Motocicleta de otras marcas

OHVALE

OHVALE GP-0 Manual de lista de piezas

KTM

KTM 350 XCF-W USA Manual de usuario

HYOSUNG

HYOSUNG ST7 Manual de usuario

Husqvarna

Husqvarna FC 250 2016 Manual de usuario

Ducati

Ducati SCRAMBLER 800 Manual de instrucciones

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES Manual de usuario

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Manual de usuario

KTM

KTM Freeride E-XC 2021 Manual de usuario

Fantic

Fantic Enduro 125 Manual de usuario

Ducati

Ducati Supersport 750 desmodue Manual de usuario

MV Agusta

MV Agusta 2008 F4 312RR 1078 Manual de instrucciones

Ducati

Ducati 748 monoposto strada Manual de usuario

ATK

ATK 1988 250 Manual de usuario

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Manual de usuario

Triumph

Triumph Thunderbird Manual de usuario

Ducati

Ducati 996 Manual de usuario

BMW

BMW MOTORRAD K 1200 R Sport Manual de instalación y mantenimiento

BMW Motorrad

BMW Motorrad G 650 GS 2007 Manual de instalación y mantenimiento