Yamaha 2004 YP400 Manuals

Manuals and User Guides for Yamaha 2004 YP400. We have 1 Yamaha 2004 YP400 manual available for free PDF download: Service Manual

Yamaha 2004 YP400 Service Manual

Yamaha 2004 YP400 Service Manual (417 pages)

Yamaha YP400(S) Scooter Service manual

Brand: Yamaha | Category: Scooter | Size: 16.18 MB

Table of Contents

Table of Contents

7
- Chassis
  6
  - Table of Contents
    7
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Chapter 1 General Information
  12
- Scooter Identification
  12
  - Vehicle Identification Number
    12
  - Model Label
    12
- Features
  13
  - Outline of Fi System
    13
  - Fi System
    14
  - Instrument Function
    15
- Important Information
  21
  - Preparation for Removal and Disassembly
    21
  - Replacement Parts
    21
  - Gaskets, Oil Seals and O-Rings
    21
  - Lock Washers/Plates and Cotter Pins
    22
  - Bearings and Oil Seals
    22
  - Circlips
    22
- Checking the Connections
  23
- Special Tools
  24
Chapter 2 Specifications

29
- General Specifications
  31
- Engine
  32
  - Engine Specifications
    32
- Spec
  33
Chapter 3 Periodic Checks and Adjustments

78
- Introduction
  80
- Periodic Maintenance and Lubrication Chart
  80
- Cowling and Covers
  82
- Air Filter Cases
  88
- Engine
  89
  - Adjusting the Valve Clearance
    89
  - Adjusting the Exhaust Gas Volume
    94
  - Checking the Engine Idling Speed
    95
  - Adjusting the Throttle Cable Free Play
    96
  - Checking the Spark Plug
    96
  - Checking the Ignition Timing
    98
  - Measuring the Compression Pressure
    99
  - Checking the Engine Oil Level
    101
  - Changing the Engine Oil
    102
  - Changing the Transmission Oil
    105
  - Replacing the Air Filter Elements
    106
  - Changing the Transmission Oil
    106
  - Cleaning the V-Belt Case Air Filter Element
    107
  - Checking the Throttle Body Joint and Intake Manifold
    108
  - Checking the Fuel Hose
    108
  - Checking the Breather Hoses
    109
  - Checking the Exhaust System
    110
  - Checking the Coolant Level
    110
  - Checking the Cooling System
    111
  - Changing the Coolant
    112
- Chassis
  115
  - Adjusting the Rear Brake Lock Lever Cable
    115
  - Checking the Brake Fluid Level
    116
  - Checking the Front and Rear Brake Pads
    117
  - Checking the Front and Rear Brake Hoses
    117
  - Bleeding the Hydraulic Brake System
    118
  - Checking and Adjusting the Steering Head
    119
  - Checking the Front Fork
    121
  - Checking the Tires
    122
  - Checking the Wheels
    125
  - Checking and Lubricating the Cables
    125
  - Lubricating the Levers
    126
  - Lubricating the Sidestand
    126
  - Lubricating the Centerstand
    126
- Chk Adj
  127
- Electrical System
  127
  - Checking and Charging the Battery
    127
  - Checking the Fuses
    132
  - Replacing the Headlight Bulbs
    134
  - Adjusting the Headlight Beams
    136
- Chas
  138
Chapter 4 Chassis

139
- Front Wheel and Brake Disc
  141
- Checking the Front Wheel
  143
- Removing the Front Wheel
  143
- Checking the Brake Discs
  144
- Installing the Front Wheel
  146
- Adjusting the Front Wheel Static Balance
  147
- Rear Wheel and Brake Disc
  149
  - Removing the Rear Wheel
    150
  - Checking the Rear Wheel
    150
  - Adjusting the Rear Wheel Static Balance
    150
- Front and Rear Brakes
  151
- Front Fork
  184
  - Removing the Front Fork Legs
    188
  - Disassembling the Front Fork Legs
    188
  - Checking the Front Fork Legs
    190
  - Assembling the Front Fork Legs
    190
  - Installing the Front Fork Legs
    193
- Handlebar
  194
  - Removing the Handlebar
    196
  - Checking the Handlebar
    196
  - Installing the Handlebar
    196
- Steering Head
  200
  - Lower Bracket
    200
  - Removing the Lower Bracket
    202
  - Checking the Steering Head
    203
  - Installing the Steering Head
    204
- Rear Shock Absorber Assemblies and Swingarm
  205
- Eng
  211
Chapter 5 Engine

212
- Engine Removal
  214
  - Leads, Hoses, Exhaust Pipe and Muffler
    214
  - Engine
    216
  - Installing the Engine
    218
- Camshafts
  219
  - Cylinder Head Cover
    219
  - Camshafts
    220
  - Removing the Camshafts
    222
  - Checking the Camshafts
    223
  - Checking the Camshaft Sprockets
    225
  - Checking the Decompression System
    225
  - Checking the Timing Chain Tensioner
    226
  - Installing the Camshafts
    226
- Cylinder Head
  230
- Valves and Valve Springs
  234
  - Removing the Valves
    235
  - Checking the Valves and Valve Guides
    236
  - Checking the Valve Seats
    238
  - Checking the Valve Springs
    240
  - Checking the Valve Lifters
    241
  - Installing the Valves
    241
- Cylinder and Piston
  243
  - Removing the Piston
    244
  - Checking the Cylinder and Piston
    244
  - Checking the Piston Rings
    246
  - Checking the Piston Pin
    247
  - Installing the Piston and Cylinder
    247
- Belt Drive
  250
  - V-Belt Case Cover
    250
  - V-Belt and Primary/Secondary Sheave
    251
  - Removing the Primary Sheave
    255
  - Removing the Secondary Sheave and V-Belt
    255
  - Disassembling the Secondary Sheave
    256
  - Checking the V-Belt
    257
  - Checking the V-Belt Case Air Ducts
    257
  - Checking the Primary Sheave
    257
  - Checking the Primary Sheave Weights
    257
  - Checking the Secondary Sheave
    258
  - Checking the Clutch Shoes
    258
  - Assembling the Primary Sheave
    259
  - Assembling the Secondary Sheave
    259
  - Installing the Secondary Sheave, V-Belt and Primary Sheave
    260
- Starter Clutch and Generator
  262
  - Generator Rotor Cover and Stator Coil
    262
  - Removing the Generator
    265
  - Checking the Starter Clutch
    266
  - Installing the Starter Clutch
    267
  - Installing the Generator
    267
- Oil Pump
  269
  - Checking the Oil Pump
    270
  - Checking the Oil Pump Drive Chain
    270
  - Assembling the Oil Pump
    271
  - Installing the Oil Pump
    271
- Crankshaft
  272
- Transmission
  283
  - Checking the Transmission
    285
  - Installing the Primary Drive Gear Oil Seal
    285
- Cool
  286
6 Cool

287
- Chapter 6 Cooling System
  289
- Radiator
  289
  - Checking the Radiator
    290
  - Installing the Radiator
    291
- Thermostat
  292
  - Checking the Thermostat
    293
  - Installing the Thermostat
    294
- Water Pump and Oil Cooler
  295
  - Checking the Water Pump
    297
  - Checking the Oil Cooler
    297
  - Assembling the Water Pump
    298
Chapter 7 Fuel Injection System

300
- Wiring Diagram
  303
- Ecu's Self-Diagnostic Function
  304
- Fuel Injection System Fi
  304
- Alternate Instructions Operation Control (Fail-Safe Action)
  305
- Fail-Safe Actions Table
  305
- Fuel Injection System Fi
  305
- Troubleshooting Chart
  307
- Diagnostic Mode
  308
- Troubleshooting Details
  313
- Throttle Body and Fuel Injector
  326
  - Fuel Hose
    328
  - Fuel Tank
    329
  - Removing the Fuel Hose
    331
  - Removing the Fuel Pump
    331
  - Checking the Fuel Injector
    332
  - Checking the Throttle Body
    332
  - Installing the Fuel Pump
    333
  - Installing the Sub-Frame
    333
  - Installing the Fuel Hose
    334
  - Checking the Fuel Pump and Pressure Regulator Operation
    335
  - Checking the Throttle Position Sensor
    335
  - Checking the Isc (Idle Speed Control) Valve
    337
- Air Induction System
  338
  - Air Injection
    338
  - Air Cut-Off Valve
    338
  - Air Induction System Diagrams
    339
  - Air Cut-Off Valve and Air Induction System Hoses
    340
  - Checking the Air Induction System
    341
- Elec
  342
Chapter 8 Electrical System

343
- Electrical Components
  345
- Checking Switch Continuity
  347
- Checking the Switches
  348
- Checking the Bulbs and Bulb Sockets
  349
  - Types of Bulbs
    349
  - Checking the Condition of the Bulbs
    350
  - Checking the Condition of the Bulb Sockets
    351
  - CHECKING the Leds
    351
- Ignition System
  352
  - Circuit Diagram
    352
  - Troubleshooting
    353
- Electric Starting System
  358
  - Circuit Diagram
    358
  - Starting Circuit Cut-Off System Operation
    359
  - Troubleshooting
    360
- Starter Motor
  363
  - Checking the Starter Motor
    365
  - Assembling the Starter Motor
    366
- Charging System
  367
  - Circuit Diagram
    367
  - Troubleshooting
    368
- Lighting System
  370
  - Circuit Diagram
    370
  - Troubleshooting
    371
  - Checking the Lighting System
    374
- Signaling System
  379
  - Circuit Diagram
    379
  - Troubleshooting
    381
  - Checking the Signaling System
    382
- Cooling System
  389
  - Circuit Diagram
    389
  - Troubleshooting
    390
- Immobilizer System
  393
  - System Diagram
    393
  - General Information
    395
  - Key Code Registration
    396
  - Self-Diagnosis Malfunction Codes
    398
  - Troubleshooting
    400
  - Checking the Immobilizer System
    401
  - Part Replacement Key Registration Requirements
    403
- Trbl Shtg
  405
Trbl Shtg

406
- Chapter 9 Troubleshooting
  408
- Starting Failure/Hard Starting
  408
  - Engine
    408
  - Fuel System
    408
  - Electrical Systems
    409
- Incorrect Engine Idling Speed
  409
  - Engine
    409
  - Fuel System
    409
- Faulty Clutch
  410
  - Engine Operates but Scooter will Not Move
    410
  - Clutch Slips
    410
  - Poor Starting Performance
    410
  - Poor Speed Performance
    410
- Poor Medium-And-High-Speed Performance
  410
  - Engine
    410
  - Fuel System
    410
- Overcooling
  411
- Overheating
  411
  - Engine
    411
  - Cooling System
    411
  - Fuel System
    411
  - Chassis
    411
  - Electrical Systems
    411
- Faulty Front Fork Legs
  412
  - Leaking Oil
    412
  - Malfunction
    412
- Poor Braking Performance
  412
- Unstable Handling
  412

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