Yamaha YP400T Manuals

Manuals and User Guides for Yamaha YP400T. We have 3 Yamaha YP400T manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha YP400T Service Manual

Yamaha YP400T Service Manual (387 pages)

Brand: Yamaha | Category: Motorcycle | Size: 16.17 MB

Table of Contents

How to Use this Manual
4
General Information

5
Specifications

5
- Table of Contents
  6
Periodic Checks and Adjustments

5
Chassis

5
Engine

5
Cooling System

5
Fuel Injection System

5
Electrical System

5
Troubleshooting

15
Scooter Identification

17
- Vehicle Identification Number
  17
- Model Label
  17
Chapter 1 General Information

17
Features

18
- Outline of the Fi System
  18
- Fi System
  19
- Instrument Functions
  20
Important Information

26
- Preparation for Removal and Disassembly
  26
- Replacement Parts
  26
- Gaskets, Oil Seals and O-Rings
  26
- Lock Washers/Plates and Cotter Pins
  27
- Bearings and Oil Seals
  27
- Circlips
  27
Checking the Connections

28
Special Tools

29
Chapter 2 Specifications

33
Spec

33
General Specifications

33
Engine Specifications

34
Chassis Specifications

42
Electrical Specifications

46
Conversion Table

49
General Tightening Torque Specifications

49
Tightening Torques

52
- Chassis Tightening Torques
  53
Lubrication Points and Lubricant Types

55
- Engine Lubrication Points and Lubricant Types
  55
- Chassis Lubrication Points and Lubricant Types
  57
Cooling System Diagrams

58
Cable Routing

60
Chapter 3 Periodic Checks and Adjustments

81
Introduction

81
Periodic Maintenance Chart for the Emission Control System

81
Chk Adj

81
General Maintenance and Lubrication Chart

82
Cowling and Covers

84
Air Filter Cases

90
Engine

91
- Adjusting the Valve Clearance
  91
- Adjusting the Exhaust Gas Volume
  96
- Checking the Engine Idling Speed
  97
- Adjusting the Throttle Cable Free Play
  98
- Checking the Spark Plug
  98
- Checking the Ignition Timing
  100
- Measuring the Compression Pressure
  101
- Checking the Engine Oil Level
  103
- Changing the Engine Oil
  104
- Changing the Transmission Oil
  107
- Replacing the Air Filter Elements
  108
- Cleaning the V-Belt Case Air Filter Element
  109
- Checking the Throttle Body Joint and Intake Manifold
  110
- Checking the Fuel Hose
  110
- Checking the Breather Hoses
  111
- Checking the Exhaust System
  112
- Checking the Coolant Level
  112
- Checking the Cooling System
  113
- Changing the Coolant
  114
Chassis

117
- Adjusting the Rear Brake Lock Lever Cable
  117
- Checking the Brake Fluid Level
  118
- Checking the Front and Rear Brake Pads
  119
- Checking the Front and Rear Brake Hoses
  119
- Bleeding the Hydraulic Brake System
  120
- Checking and Adjusting the Steering Head
  121
- Checking the Front Fork
  123
- Checking the Tires
  124
- Checking the Wheels
  127
- Checking and Lubricating the Cables
  127
- Lubricating the Levers
  128
- Lubricating the Sidestand
  128
- Lubricating the Centerstand
  128
Electrical System

129
- Checking and Charging the Battery
  129
- Checking the Fuses
  134
- Replacing the Headlight Bulbs
  136
- Adjusting the Headlight Beams
  138
Chapter 4 Chassis

139
Front Wheel and Brake Disc

139
- Removing the Front Wheel
  141
- Checking the Front Wheel
  141
- Checking the Brake Discs
  142
- Installing the Front Wheel
  144
- Adjusting the Front Wheel Static Balance
  145
Chas

139
Rear Wheel and Brake Disc

147
- Removing the Rear Wheel
  148
- Checking the Rear Wheel
  148
- Adjusting the Rear Wheel Static Balance
  148
Front and Rear Brakes

149
Front Fork

182
- Removing the Front Fork Legs
  186
- Disassembling the Front Fork Legs
  186
- Checking the Front Fork Legs
  188
- Assembling the Front Fork Legs
  188
- Installing the Front Fork Legs
  191
Handlebar

192
- Removing the Handlebar
  194
- Checking the Handlebar
  194
- Installing the Handlebar
  194
Steering Head

198
- Lower Bracket
  198
- Removing the Lower Bracket
  200
- Checking the Steering Head
  201
- Installing the Steering Head
  202
Rear Shock Absorber Assemblies and Swingarm

203
Chapter 5 Engine

208
Engine Removal

208
- Leads, Hoses, Exhaust Pipe and Muffler
  208
- Engine
  210
- Installing the Engine
  212
Eng

208
Camshafts

213
- Cylinder Head Cover
  213
- Camshafts
  214
- Removing the Camshafts
  216
- Checking the Camshafts
  217
- Checking the Camshaft Sprockets
  219
- Checking the Decompression System
  219
- Checking the Timing Chain Tensioner
  220
- Installing the Camshafts
  220
Cylinder Head

224
Valves and Valve Springs

228
- Removing the Valves
  229
- Checking the Valves and Valve Guides
  230
- Checking the Valve Seats
  232
- Checking the Valve Springs
  234
- Checking the Valve Lifters
  235
- Installing the Valves
  235
Cylinder and Piston

237
- Removing the Piston
  238
- Checking the Cylinder and Piston
  238
- Checking the Piston Rings
  240
- Checking the Piston Pin
  241
- Installing the Piston and Cylinder
  241
Belt Drive

244
- V-Belt Case Cover
  244
- V-Belt and Primary/Secondary Sheave
  245
- Secondary Sheave
  247
- Removing the Primary Sheave
  249
- Removing the Secondary Sheave and V-Belt
  249
- Disassembling the Secondary Sheave
  250
- Checking the V-Belt
  251
- Checking the V-Belt Case Air Ducts
  251
- Checking the Primary Sheave
  251
- Checking the Primary Sheave Weights
  251
- Checking the Secondary Sheave
  252
- Checking the Clutch Shoes
  252
- Assembling the Primary Sheave
  253
- Assembling the Secondary Sheave
  253
- Installing the Secondary Sheave, V-Belt and Primary Sheave
  254
Starter Clutch and Generator

256
- Generator Rotor Cover and Stator Coil
  256
- Starter Clutch and Generator
  259
- Removing the Generator
  259
- Checking the Starter Clutch
  260
- Installing the Starter Clutch
  261
- Installing the Generator
  261
Oil Pump

263
- Checking the Oil Pump
  264
- Checking the Oil Pump Drive Chain
  264
- Assembling the Oil Pump
  265
- Installing the Oil Pump
  265
Crankshaft

266
Transmission

278
- Checking the Transmission
  280
- Installing the Primary Drive Gear Oil Seal
  280
Chapter 6 Cooling System

281
Cool

281
Radiator

281
- Checking the Radiator
  282
- Installing the Radiator
  283
Thermostat

284
- Checking the Thermostat
  285
- Installing the Thermostat
  286
Water Pump and Oil Cooler

287
- Checking the Water Pump
  289
- Checking the Oil Cooler
  289
- Assembling the Water Pump
  290
Chapter 7 Fuel Injection System

291
- Wiring Diagram
  292
- Ecu's Self-Diagnostic Function
  293
- Alternate Instructions Operation Control (Fail-Safe Action)
  294
- Fail-Safe Actions Table
  294
- Troubleshooting Chart
  296
- Diagnostic Mode
  297
- Troubleshooting Details
  302
Throttle Body and Fuel Injector

315
- Fuel Hose
  317
- Fuel Tank
  318
- Removing the Fuel Hose
  320
- Removing the Fuel Pump
  320
- Checking the Fuel Injector
  321
- Checking the Throttle Body
  321
- Installing the Fuel Pump
  322
- Installing the Sub-Frame
  322
- Installing the Fuel Hose
  323
- Checking the Fuel Pump and Pressure Regulator Operation
  324
- Checking the Throttle Position Sensor
  324
- Checking the Isc (Idle Speed Control) Valve
  326
Air Induction System

327
- Air Injection
  327
- Air Cut-Off Valve
  327
- Air Induction System Diagrams
  328
- Air Cut-Off Valve and Air Induction System Hoses
  329
- Checking the Air Induction System
  330
Canister

331
Chapter 8 Electrical System

332
Elec

332
Electrical Components

332
Checking Switch Continuity

334
Checking the Switches

335
Checking the Bulbs and Bulb Sockets

336
Ignition System

339
- Circuit Diagram
  339
- Troubleshooting
  340
Electric Starting System

345
- Circuit Diagram
  345
- Starting Circuit Cut-Off System Operation
  346
- Troubleshooting
  347
Starter Motor

350
- Checking the Starter Motor
  352
- Assembling the Starter Motor
  353
Charging System

354
- Circuit Diagram
  354
- Troubleshooting
  355
- Charging System
  356
Lighting System

357
- Circuit Diagram
  357
- Troubleshooting
  358
- Checking the Lighting System
  360
Signaling System

365
- Circuit Diagram
  365
- Troubleshooting
  367
- Checking the Signaling System
  368
- Signaling System
  370
Cooling System

375
- Circuit Diagram
  375
Chapter 9

379
- Engine
  379
- Fuel System
  379
- Electrical Systems
  380
Trbl Shtg

379
- Troubleshooting
  379
Starting Failure/Hard Starting

379
Incorrect Engine Idling Speed

380
- Engine
  380
- Fuel System
  380
Poor Medium-And-High-Speed Performance

381
- Engine
  381
- Fuel System
  381
Faulty Clutch

381
- Engine Operates but Scooter will Not Move
  381
- Clutch Slips
  381
- Poor Starting Performance
  381
- Poor Speed Performance
  381
Overheating

382
- Engine
  382
- Cooling System
  382
- Fuel System
  382
- Chassis
  382
- Electrical Systems
  382
Overcooling

382
Poor Braking Performance

383
Faulty Front Fork Legs

383
- Leaking Oil
  383
- Malfunction
  383
Unstable Handling

383
Faulty Lighting or Signaling System

384
- Headlight Does Not Come on
  384
- Headlight Bulb Burnt out
  384
- Tail/Brake Light Does Not Come on
  384
- Tail/Brake Light Bulb Burnt out
  384
- Turn Signal Does Not Come on
  384
- Turn Signal Blinks Slowly
  384
- Turn Signal Remains Lit
  384
- Turn Signal Blinks Quickly
  384
- Horn Does Not Sound
  384

Advertisement

Yamaha YP400T Service Manual

Yamaha YP400T Service Manual (390 pages)

2005-2007 years

Brand: Yamaha | Category: Motorcycle | Size: 13.87 MB

Table of Contents

Gen Info

6
- Important Manual Information
  3
- How to Use this Manual
  4
- Table of Contents
  6
- Chapter 1 General Information
  7
- Scooter Identification
  7
  - Vehicle Identification Number
    7
  - Model Label
    7
- Features
  8
  - Outline of the Fi System
    8
  - Fi System
    9
  - Instrument Functions
    10
- Important Information
  16
  - Preparation for Removal and Disassembly
    16
  - Replacement Parts
    16
  - Gaskets, Oil Seals and O-Rings
    16
  - Lock Washers/Plates and Cotter Pins
    17
  - Bearings and Oil Seals
    17
  - Circlips
    17
- Checking the Connections
  18
- Special Tools
  19
Chapter 2 Specifications

23
- General Specifications
  24
- Engine Specifications
  25
- Chassis Specifications
  33
- Electrical Specifications
  37
- Conversion Table
  40
- General Tightening Torque Specifications
  40
- Tightening Torques
  41
  - Engine Tightening Torques
    41
  - Chassis Tightening Torques
    44
- Lubrication Points and Lubricant Types
  46
  - Engine Lubrication Points and Lubricant Types
    46
  - Chassis Lubrication Points and Lubricant Types
    48
- Cooling System Diagrams
  49
- Cable Routing
  51
Chapter 3 Periodic Checks and Adjustments

72
- Introduction
  74
- Periodic Maintenance Chart for the Emission Control System
  74
- General Maintenance and Lubrication Chart
  75
- Cowling and Covers
  77
- Air Filter Cases
  83
- Engine
  84
  - Adjusting the Valve Clearance
    84
  - Adjusting the Exhaust Gas Volume
    89
  - Checking the Engine Idling Speed
    90
  - Adjusting the Throttle Cable Free Play
    91
  - Checking the Spark Plug
    91
  - Checking the Ignition Timing
    93
  - Measuring the Compression Pressure
    94
  - Checking the Engine Oil Level
    96
  - Changing the Engine Oil
    97
  - Changing the Transmission Oil
    100
  - Replacing the Air Filter Elements
    101
  - Changing the Transmission Oil
    101
  - Cleaning the V-Belt Case Air Filter Element
    102
  - Checking the Throttle Body Joint and Intake Manifold
    103
  - Checking the Fuel Hose
    103
  - Checking the Breather Hoses
    104
  - Checking the Exhaust System
    105
  - Checking the Coolant Level
    105
  - Checking the Cooling System
    106
  - Changing the Coolant
    107
- Chassis
  110
  - Adjusting the Rear Brake Lock Lever Cable
    110
  - Checking the Brake Fluid Level
    111
  - Checking the Front and Rear Brake Pads
    112
  - Checking the Front and Rear Brake Hoses
    112
  - Bleeding the Hydraulic Brake System
    113
  - Checking and Adjusting the Steering Head
    114
  - Checking the Front Fork
    116
  - Checking the Tires
    117
  - Checking the Wheels
    120
  - Checking and Lubricating the Cables
    120
  - Lubricating the Levers
    121
  - Lubricating the Sidestand
    121
  - Lubricating the Centerstand
    121
- Electrical System
  122
  - Checking and Charging the Battery
    122
  - Checking the Fuses
    127
  - Replacing the Headlight Bulbs
    129
  - Adjusting the Headlight Beams
    131
Chapter 4 Chassis

132
- Front Wheel and Brake Disc
  134
- Checking the Front Wheel
  136
- Removing the Front Wheel
  136
- Checking the Brake Discs
  137
- Installing the Front Wheel
  139
- Adjusting the Front Wheel Static Balance
  140
- Rear Wheel and Brake Disc
  142
  - Removing the Rear Wheel
    143
  - Checking the Rear Wheel
    143
  - Adjusting the Rear Wheel Static Balance
    143
- Front and Rear Brakes
  144
- Front Fork
  177
  - Removing the Front Fork Legs
    181
  - Disassembling the Front Fork Legs
    181
  - Checking the Front Fork Legs
    183
  - Assembling the Front Fork Legs
    183
  - Installing the Front Fork Legs
    186
- Handlebar
  187
  - Removing the Handlebar
    189
  - Checking the Handlebar
    189
  - Installing the Handlebar
    189
- Steering Head
  193
  - Lower Bracket
    193
  - Removing the Lower Bracket
    195
  - Checking the Steering Head
    196
  - Installing the Steering Head
    197
- Rear Shock Absorber Assemblies and Swingarm
  198
Chapter 5 Engine

203
- Engine Removal
  205
  - Leads, Hoses, Exhaust Pipe and Muffler
    205
  - Engine
    207
  - Installing the Engine
    209
- Camshafts
  210
  - Cylinder Head Cover
    210
  - Camshafts
    211
  - Removing the Camshafts
    213
  - Checking the Camshafts
    214
  - Checking the Camshaft Sprockets
    216
  - Checking the Decompression System
    216
  - Checking the Timing Chain Tensioner
    217
  - Installing the Camshafts
    217
- Cylinder Head
  221
- Valves and Valve Springs
  225
  - Removing the Valves
    226
  - Checking the Valves and Valve Guides
    227
  - Checking the Valve Seats
    229
  - Checking the Valve Springs
    231
  - Checking the Valve Lifters
    232
  - Installing the Valves
    232
- Cylinder and Piston
  234
  - Removing the Piston
    235
  - Checking the Cylinder and Piston
    235
  - Checking the Piston Rings
    237
  - Checking the Piston Pin
    238
  - Installing the Piston and Cylinder
    238
- Belt Drive
  241
  - V-Belt Case Cover
    241
  - V-Belt and Primary/Secondary Sheave
    242
  - Removing the Primary Sheave
    246
  - Removing the Secondary Sheave and V-Belt
    246
  - Disassembling the Secondary Sheave
    247
  - Checking the V-Belt
    248
  - Checking the V-Belt Case Air Ducts
    248
  - Checking the Primary Sheave
    248
  - Checking the Primary Sheave Weights
    248
  - Checking the Secondary Sheave
    249
  - Checking the Clutch Shoes
    249
  - Assembling the Primary Sheave
    250
  - Assembling the Secondary Sheave
    250
  - Installing the Secondary Sheave, V-Belt and Primary Sheave
    251
- Starter Clutch and Generator
  253
  - Generator Rotor Cover and Stator Coil
    253
  - Removing the Generator
    256
  - Checking the Starter Clutch
    257
  - Installing the Starter Clutch
    258
  - Installing the Generator
    258
- Oil Pump
  260
  - Checking the Oil Pump
    261
  - Checking the Oil Pump Drive Chain
    261
  - Assembling the Oil Pump
    262
  - Installing the Oil Pump
    262
- Crankshaft
  263
- Transmission
  275
  - Checking the Transmission
    277
  - Installing the Primary Drive Gear Oil Seal
    277
Table of Contents

278
- Chapter 6 Cooling System
  279
- Radiator
  279
  - Checking the Radiator
    280
  - Installing the Radiator
    281
- Thermostat
  282
  - Checking the Thermostat
    283
  - Installing the Thermostat
    284
- Water Pump and Oil Cooler
  285
  - Checking the Water Pump
    287
  - Checking the Oil Cooler
    287
  - Assembling the Water Pump
    288
Chapter 7 Fuel Injection System

289
- Wiring Diagram
  291
- Ecu's Self-Diagnostic Function
  292
- Alternate Instructions Operation Control (Fail-Safe Action)
  293
- Fail-Safe Actions Table
  293
- Troubleshooting Chart
  295
- Diagnostic Mode
  296
- Troubleshooting Details
  301
- Throttle Body and Fuel Injector
  314
  - Fuel Hose
    316
  - Fuel Tank
    317
  - Removing the Fuel Hose
    319
  - Removing the Fuel Pump
    319
  - Checking the Fuel Injector
    320
  - Checking the Throttle Body
    320
  - Installing the Fuel Pump
    321
  - Installing the Sub-Frame
    321
  - Installing the Fuel Hose
    322
  - Checking the Fuel Pump and Pressure Regulator Operation
    323
  - Checking the Throttle Position Sensor
    323
  - Checking the Isc (Idle Speed Control) Valve
    325
- Air Induction System
  326
  - Air Injection
    326
  - Air Cut-Off Valve
    326
  - Air Induction System Diagrams
    327
  - Air Cut-Off Valve and Air Induction System Hoses
    328
  - Checking the Air Induction System
    329
- Canister
  330
Chapter 8 Electrical System

331
- Electrical Components
  332
- Checking Switch Continuity
  334
- Checking the Switches
  335
- Checking the Bulbs and Bulb Sockets
  336
- Ignition System
  339
  - Circuit Diagram
    339
  - Troubleshooting
    340
- Electric Starting System
  345
  - Circuit Diagram
    345
  - Starting Circuit Cut-Off System Operation
    346
  - Troubleshooting
    347
- Starter Motor
  350
  - Checking the Starter Motor
    352
  - Assembling the Starter Motor
    353
- Charging System
  354
  - Circuit Diagram
    354
  - Troubleshooting
    355
- Lighting System
  357
  - Circuit Diagram
    357
  - Troubleshooting
    358
  - Checking the Lighting System
    360
- Signaling System
  366
  - Circuit Diagram
    366
  - Troubleshooting
    368
  - Checking the Signaling System
    369
- Cooling System
  376
  - Circuit Diagram
    376
Trbl Shtg

380
- Troubleshooting
  380
- Chapter 9
  382
- Engine
  382
- Fuel System
  382
- Starting Failure/Hard Starting
  382
- Electrical Systems
  383
- Incorrect Engine Idling Speed
  383
  - Engine
    383
  - Fuel System
    383
- Faulty Clutch
  384
  - Engine Operates but Scooter will Not Move
    384
  - Clutch Slips
    384
  - Poor Starting Performance
    384
  - Poor Speed Performance
    384
- Poor Medium-And-High-Speed Performance
  384
  - Engine
    384
  - Fuel System
    384
- Overcooling
  385
- Overheating
  385
  - Engine
    385
  - Cooling System
    385
  - Fuel System
    385
  - Chassis
    385
  - Electrical Systems
    385
- Faulty Front Fork Legs
  386
  - Leaking Oil
    386
  - Malfunction
    386
- Poor Braking Performance
  386
- Unstable Handling
  386
  - Faulty Lighting or Signaling System
    387

Yamaha YP400T Owner's Manual

Yamaha YP400T Owner's Manual (101 pages)

Brand: Yamaha | Category: Scooter | Size: 2.73 MB

Table of Contents

Table of Contents
6
Safety Information
8
Further Safe-Riding Points
11
Location of Important Labels
13
Description
16
Left View
16
Right View
17
Controls and Instruments
18
Main Switch/Steering Lock
19
Instrument and Control Functions
19
Indicator and Warning Lights
20
Speedometer
20
Tachometer
21
Multi-Function Display
21
Handlebar Switches
24
Front Brake Lever
25
Rear Brake Lever
26
Rear Brake Lock Lever
26
Fuel Tank Cap
27
Fuel
28
Catalytic Converter
29
Seats
29
Adjusting the Rider Seat
30
Storage Compartments
31
Sidestand
32
Ignition Circuit Cut-Off System
33
Pre-Operation Checks
35
Pre-Operation Check List
36
- Operation and Important Riding Points
  38
- Starting the Engine
  38
  - Starting off
    39
  - Acceleration and Deceleration
    39
- Braking
  39
- Engine Break-In
  40
- Parking
  41
  - Periodic Maintenance and Minor Repair
    42
- Periodic Maintenance
  42
- Removing and Installing Cowlings and Panels
  49
Checking the Spark Plug
53
Canister
55
Engine Oil and Oil Filter Element
55
Reset Oil Change Indicator
57
Final Transmission Oil
58
Coolant
59
Air Filter Elements and Check Hoses and V-Belt Case Air Filter Element
61
Adjusting the Throttle Cable Free Play
64
Adjusting the Valve Clearance
64
Tires
64
- Cast Wheels
  66
- Accessories and Replacement Parts
  67
- Front and Rear Brake Lever Free Play
  67
- Adjusting the Rear Brake Lock Lever Cable
  68
- Checking the Front and Rear Brake
  68
- Pads
  68
- Checking the Brake Fluid Level
  69
- Changing the Brake Fluid
  70
- Checking and Lubricating the Cables
  70
- Checking and Lubricating the Throttle Grip and Cable
  71
- Lubricating the Front and Rear Brake Levers
  71
- Checking and Lubricating the Centerstand and Sidestand
  71
- Checking the Front Fork
  72
- Checking the Steering
  73
- Checking the Wheel Bearings
  73
- Battery
  74
- Replacing the Fuses
  75
- Replacing a Headlight Bulb
  77
- Tail/Brake Light
  77
- Replacing a Front Turn Signal Light Bulb
  77
- Replacing a Rear Turn Signal Light Bulb
  78
- Replacing the License Plate Light Bulb
  79
- Troubleshooting
  80
- Troubleshooting Charts
  81
- Scooter Care and Storage
  83
- Care
  83
- Storage
  85
- Specifications
  87
- Consumer Information
  90
- Identification Numbers
  90
- Scooter Noise Regulation
  92
- Maintenance Record
  93
- Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
  95
- Yamaha Extended Service (Y.e.s.)
  97

Advertisement

Advertisement

Related Products

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals