Yamaha YP400T User Manual (English)

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

YP400T

SERVICE MANUAL

Default Chapter4
- How to Use this Manual4
General Information5
Specifications5
- Table of Contents6
Periodic Checks and Adjustments5
Chassis5
Engine5
Cooling System5
Fuel Injection System5
Electrical System5
Troubleshooting15
Scooter Identification17
- Vehicle Identification Number17
- Model Label17
Chapter 1 General Information17
Features18
- Outline of the Fi System18
- Fi System19
- Instrument Functions20
Important Information26
- Preparation for Removal and Disassembly26
- Replacement Parts26
- Gaskets, Oil Seals and O-Rings26
- Lock Washers/Plates and Cotter Pins27
- Bearings and Oil Seals27
- Circlips27
Checking the Connections28
Special Tools29
Chapter 2 Specifications33
Spec33
General Specifications33
Engine Specifications34
Chassis Specifications42
Electrical Specifications46
Conversion Table49
General Tightening Torque Specifications49
Tightening Torques52
- Chassis Tightening Torques53
Lubrication Points and Lubricant Types55
- Engine Lubrication Points and Lubricant Types55
- Chassis Lubrication Points and Lubricant Types57
Cooling System Diagrams58
Cable Routing60
Chapter 3 Periodic Checks and Adjustments81
Introduction81
Periodic Maintenance Chart for the Emission Control System81
Chk Adj81
General Maintenance and Lubrication Chart82
Cowling and Covers84
- Passenger Seat and Side Covers84
- Rider Seat and Storage Box85
- Side Cover Mouldings and Footrest Boards87
- Front Cowling88
Air Filter Cases90
Engine91
- Adjusting the Valve Clearance91
- Adjusting the Exhaust Gas Volume96
- Checking the Engine Idling Speed97
- Adjusting the Throttle Cable Free Play98
- Checking the Spark Plug98
- Checking the Ignition Timing100
- Measuring the Compression Pressure101
- Checking the Engine Oil Level103
- Changing the Engine Oil104
- Changing the Transmission Oil107
- Replacing the Air Filter Elements108
- Cleaning the V-Belt Case Air Filter Element109
- Checking the Throttle Body Joint and Intake Manifold110
- Checking the Fuel Hose110
- Checking the Breather Hoses111
- Checking the Exhaust System112
- Checking the Coolant Level112
- Checking the Cooling System113
- Changing the Coolant114
Chassis117
- Adjusting the Rear Brake Lock Lever Cable117
- Checking the Brake Fluid Level118
- Checking the Front and Rear Brake Pads119
- Checking the Front and Rear Brake Hoses119
- Bleeding the Hydraulic Brake System120
- Checking and Adjusting the Steering Head121
- Checking the Front Fork123
- Checking the Tires124
- Checking the Wheels127
- Checking and Lubricating the Cables127
- Lubricating the Levers128
- Lubricating the Sidestand128
- Lubricating the Centerstand128
Electrical System129
- Checking and Charging the Battery129
- Checking the Fuses134
- Replacing the Headlight Bulbs136
- Adjusting the Headlight Beams138
Chapter 4 Chassis139
Front Wheel and Brake Disc139
- Removing the Front Wheel141
- Checking the Front Wheel141
- Checking the Brake Discs142
- Installing the Front Wheel144
- Adjusting the Front Wheel Static Balance145
Chas139
Rear Wheel and Brake Disc147
- Removing the Rear Wheel148
- Checking the Rear Wheel148
- Adjusting the Rear Wheel Static Balance148
Front and Rear Brakes149
- Front Brake Pads149
- Rear Brake Pads150
- Replacing the Front Brake Pads151
- Replacing the Rear Brake Pads153
- Front Brake Master Cylinder156
- Rear Brake Master Cylinder159
- Disassembling the Rear Brake Master Cylinder161
- Checking the Front and Rear Brake Master Cylinders163
- Assembling and Installing the Front Brake Master Cylinder164
- Assembling and Installing the Rear Brake Master Cylinder166
- Front Brake Caliper169
- Rear Brake Caliper171
- Disassembling the Rear Brake Caliper173
- Checking the Front and Rear Brake Calipers175
- Assembling and Installing the Front Brake Caliper177
- Assembling and Installing the Rear Brake Caliper179
Front Fork182
- Removing the Front Fork Legs186
- Disassembling the Front Fork Legs186
- Checking the Front Fork Legs188
- Assembling the Front Fork Legs188
- Installing the Front Fork Legs191
Handlebar192
- Removing the Handlebar194
- Checking the Handlebar194
- Installing the Handlebar194
Steering Head198
- Lower Bracket198
- Removing the Lower Bracket200
- Checking the Steering Head201
- Installing the Steering Head202
Rear Shock Absorber Assemblies and Swingarm203
- Removing the Rear Shock Absorber Assemblies205
- Checking the Rear Shock Absorber Assemblies205
- Installing the Rear Shock Absorber Assemblies205
- Removing the Swingarm206
- Checking the Swingarm206
- Installing the Swingarm207
Chapter 5 Engine208
Engine Removal208
- Leads, Hoses, Exhaust Pipe and Muffler208
- Engine210
- Installing the Engine212
Eng208
Camshafts213
- Cylinder Head Cover213
- Camshafts214
- Removing the Camshafts216
- Checking the Camshafts217
- Checking the Camshaft Sprockets219
- Checking the Decompression System219
- Checking the Timing Chain Tensioner220
- Installing the Camshafts220
Cylinder Head224
- Removing the Cylinder Head226
- Checking the Cylinder Head226
- Checking the Timing Chain Guide (Exhaust Side)227
- Installing the Cylinder Head227
Valves and Valve Springs228
- Removing the Valves229
- Checking the Valves and Valve Guides230
- Checking the Valve Seats232
- Checking the Valve Springs234
- Checking the Valve Lifters235
- Installing the Valves235
Cylinder and Piston237
- Removing the Piston238
- Checking the Cylinder and Piston238
- Checking the Piston Rings240
- Checking the Piston Pin241
- Installing the Piston and Cylinder241
Belt Drive244
- V-Belt Case Cover244
- V-Belt and Primary/Secondary Sheave245
- Secondary Sheave247
- Removing the Primary Sheave249
- Removing the Secondary Sheave and V-Belt249
- Disassembling the Secondary Sheave250
- Checking the V-Belt251
- Checking the V-Belt Case Air Ducts251
- Checking the Primary Sheave251
- Checking the Primary Sheave Weights251
- Checking the Secondary Sheave252
- Checking the Clutch Shoes252
- Assembling the Primary Sheave253
- Assembling the Secondary Sheave253
- Installing the Secondary Sheave, V-Belt and Primary Sheave254
Starter Clutch and Generator256
- Generator Rotor Cover and Stator Coil256
- Starter Clutch and Generator259
- Removing the Generator259
- Checking the Starter Clutch260
- Installing the Starter Clutch261
- Installing the Generator261
Oil Pump263
- Checking the Oil Pump264
- Checking the Oil Pump Drive Chain264
- Assembling the Oil Pump265
- Installing the Oil Pump265
Crankshaft266
- Crankshaft Assembly and Balancer Shaft Assembly266
- Crankcase Bearings268
- Disassembling the Crankcase269
- Removing the Crankshaft Journal Bearings269
- Checking the Crankshaft and Connecting Rod270
- Checking the Balancer Shaft Assembly273
- Checking the Crankcase273
- Checking the Timing Chain and Timing Chain Guide (Intake Side)274
- Checking the Oil Pump Gears and Shafts274
- Checking the Relief Valve274
- Checking the Bearings and Oil Seals274
- Checking the Circlips and Washers275
- Installing the Crankshaft Journal Bearings275
- Installing the Crankshaft Assembly and Balancer Shaft Assembly276
- Assembling the Crankcase276
Transmission278
- Checking the Transmission280
- Installing the Primary Drive Gear Oil Seal280
Chapter 6 Cooling System281
Cool281
Radiator281
- Checking the Radiator282
- Installing the Radiator283
Thermostat284
- Checking the Thermostat285
- Installing the Thermostat286
Water Pump and Oil Cooler287
- Checking the Water Pump289
- Checking the Oil Cooler289
- Assembling the Water Pump290
Chapter 7 Fuel Injection System291
- Wiring Diagram292
- Ecu's Self-Diagnostic Function293
- Alternate Instructions Operation Control (Fail-Safe Action)294
- Fail-Safe Actions Table294
- Troubleshooting Chart296
- Diagnostic Mode297
- Troubleshooting Details302
Throttle Body and Fuel Injector315
- Fuel Hose317
- Fuel Tank318
- Removing the Fuel Hose320
- Removing the Fuel Pump320
- Checking the Fuel Injector321
- Checking the Throttle Body321
- Installing the Fuel Pump322
- Installing the Sub-Frame322
- Installing the Fuel Hose323
- Checking the Fuel Pump and Pressure Regulator Operation324
- Checking the Throttle Position Sensor324
- Checking the Isc (Idle Speed Control) Valve326
Air Induction System327
- Air Injection327
- Air Cut-Off Valve327
- Air Induction System Diagrams328
- Air Cut-Off Valve and Air Induction System Hoses329
- Checking the Air Induction System330
Canister331
Chapter 8 Electrical System332
Elec332
Electrical Components332
Checking Switch Continuity334
Checking the Switches335
Checking the Bulbs and Bulb Sockets336
- Types of Bulbs336
- Checking the Condition of the Bulbs337
- Checking the Condition of the Bulb Sockets338
Ignition System339
- Circuit Diagram339
- Troubleshooting340
Electric Starting System345
- Circuit Diagram345
- Starting Circuit Cut-Off System Operation346
- Troubleshooting347
Starter Motor350
- Checking the Starter Motor352
- Assembling the Starter Motor353
Charging System354
- Circuit Diagram354
- Troubleshooting355
- Charging System356
Lighting System357
- Circuit Diagram357
- Troubleshooting358
- Checking the Lighting System360
Signaling System365
- Circuit Diagram365
- Troubleshooting367
- Checking the Signaling System368
- Signaling System370
Cooling System375
- Circuit Diagram375
Chapter 9379
- Engine379
- Fuel System379
- Electrical Systems380
Trbl Shtg379
- Troubleshooting379
Starting Failure/Hard Starting379
Incorrect Engine Idling Speed380
- Engine380
- Fuel System380
Poor Medium-And-High-Speed Performance381
- Engine381
- Fuel System381
Faulty Clutch381
- Engine Operates but Scooter will Not Move381
- Clutch Slips381
- Poor Starting Performance381
- Poor Speed Performance381
Overheating382
- Engine382
- Cooling System382
- Fuel System382
- Chassis382
- Electrical Systems382
Overcooling382
Poor Braking Performance383
Faulty Front Fork Legs383
- Leaking Oil383
- Malfunction383
Unstable Handling383
Faulty Lighting or Signaling System384
- Headlight Does Not Come on384
- Headlight Bulb Burnt out384
- Tail/Brake Light Does Not Come on384
- Tail/Brake Light Bulb Burnt out384
- Turn Signal Does Not Come on384
- Turn Signal Blinks Slowly384
- Turn Signal Remains Lit384
- Turn Signal Blinks Quickly384
- Horn Does Not Sound384

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Yamaha YP400T Specifications

General

Displacement	395cc
Bore x Stroke	83.0 mm x 73.0 mm
Fuel System	Fuel Injection
Ignition	TCI
Transmission	V-Belt Automatic
Front Suspension	Telescopic fork
Torque	36.0 Nm (3.7 kg-m) @ 6, 250 rpm
Front Brake	Hydraulic dual disc
Rear Brake	Hydraulic disc
Front Tire	120/70-14
Fuel Capacity	14 liters