Periodic Checks And Adjustments; Introduction; Periodic Maintenance And Lubrication Chart - Yamaha 2004 YP400 Service Manual

PERIODIC MAINTENANCE AND LUBRICATION CHART

EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION CHART
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No. ITEM
Fuel line
1 *
(See page 3-29.)
Spark plug
2
(See page 3-17.)
Valves
3 *
(See page 3-10.)
Air filter element
4
(See page 3-27.)
V-belt case air fil-
5 ter element
(See page 3-28.)
Front brake
6 * (See pages 3-37,
38, 39.)
Rear brake
7 * (See pages 3-37,
38, 39.)
Rear brake lock
8
(See page 3-36.)
Brake hoses
9 *
(See page 3-38.)
Wheels
10 *
(See page 3-46.)
Tires
11 *
(See page 3-43.)
Wheel bearings
12 *
(See page 4-4.)
Steering bearings
13 *
(See page 3-40.)
Chassis fasteners
14 *
(See page 2-21.)
CHECK OR MAINTENANCE JOB
• Check fuel hoses for cracks or damage.
• Check condition.
• Clean and regap.
• Replace.
• Check valve clearance.
• Adjust.
• Replace.
• Clean.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
• Check operation.
• Adjust.
• Check for cracks or damage.
• Replace.
• Check runout and for damage.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or damage.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
INTRODUCTION/
ODOMETER READING (× 1,000 km)
1 10
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√
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3 - 1
CHK
ADJ
20 30 40
√ √ √ √
√ √
√ √
Every 40,000 km
√ √
√ √ √ √
√ √ √ √
Whenever worn to the limit
√ √ √ √
Whenever worn to the limit
√ √ √ √
√ √ √ √
Every 4 years
√ √ √ √
√ √ √ √
√ √ √ √
√ √ √ √
Every 20,000 km
√ √ √ √
ANNUAL
CHECK
√
√
√
√
√
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