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Yamaha 2004 YP400 - User Manual

Yamaha 2004 YP400
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2004
YP400(S)
5RU1-AE1
SERVICE MANUAL

Table of Contents

Questions and Answers

  • J
    Joseph OliverJul 27, 2025
    What to do if Yamaha 2004 YP400 engine operation is not normal?
    • R
      Robert GardnerJul 27, 2025
      If the engine operation is not normal or the engine trouble warning light is on, you should first check the fault code number displayed on the meter. Then, check the operation of the throttle position sensor (throttle angle), ignition coil, and fuel injector in the diagnostic mode. Identify the system with the malfunction using the 'FAIL-SAFE ACTIONS TABLE' and the probable cause using the 'Fault code table'. If a defective sensor or actuator is the cause, check and repair it. Monitor the sensors and actuators in the diagnostic mode, and perform ECU reinstatement. Finally, check the engine condition and erase the malfunction history in the diagnostic mode.

Summary

SPECIFICATIONS

ENGINE SPECIFICATIONS

Detailed engine type, displacement, bore, stroke, fuel, oil, and transmission specs.

TIGHTENING TORQUES

Specific torque values for engine and chassis fasteners with detailed item lists.

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE AND LUBRICATION CHART

Schedule of checks and maintenance jobs based on odometer reading and annual service.

ENGINE

Checks and adjustments for valve clearance, exhaust gas volume, idling speed, and spark plug.

CHASSIS

FRONT WHEEL AND BRAKE DISC

Procedures for removing, checking, installing, and balancing the front wheel and brake disc.

REAR WHEEL AND BRAKE DISC

Procedures for removing, checking, and adjusting the static balance of the rear wheel.

FRONT AND REAR BRAKES

Replacing brake pads, checking hoses, bleeding systems, and inspecting master cylinders and calipers.

FRONT FORK

Procedures for removing, disassembling, checking, and installing front fork legs.

STEERING HEAD

Procedures for removing, checking, adjusting, and installing the steering head components.

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Procedures for removing, checking, and installing rear shock absorbers and the swingarm.

ENGINE

ENGINE REMOVAL

Steps for removing leads, hoses, exhaust pipe, muffler, and the entire engine assembly.

CAMSHAFTS

Procedures for removing, checking, and installing camshafts, sprockets, and related components.

CYLINDER HEAD

Procedures for removing, checking, and installing the cylinder head, gasket, and timing chain guide.

VALVES AND VALVE SPRINGS

Procedures for removing, checking, and installing valves, springs, guides, seats, and lifters.

CYLINDER AND PISTON

Procedures for removing, checking, and installing the piston, rings, cylinder, and related parts.

BELT DRIVE

Procedures for removing, checking, assembling, and installing V-belt, sheaves, weights, and clutch components.

STARTER CLUTCH AND GENERATOR

Procedures for removing, checking, installing, and assembling the starter clutch and generator components.

OIL PUMP

Procedures for checking, assembling, and installing the oil pump and drive chain.

COOLING SYSTEM

FUEL INJECTION SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

Yamaha 2004 YP400 Specifications

General IconGeneral
Year2004
ManufacturerYamaha
ModelYP400
CategoryScooter
Displacement395 cc
Fuel SystemFuel injection
IgnitionDigital TCI
StarterElectric
TransmissionAutomatic
Final DriveV-Belt
Front SuspensionTelescopic fork
Rear SuspensionUnit swing
Rear BrakeSingle disc
Front Tire120/80-14
Rear Tire150/70-13
Wheelbase1, 590 mm
Bore x Stroke83 mm x 73 mm
Front BrakeDual discs
Width775mm
Fuel Capacity14.0 litres (3.7 US gallons)

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