User Manuals: Yamaha 2005 YP400W Scooter

Manuals and User Guides for Yamaha 2005 YP400W Scooter. We have 1 Yamaha 2005 YP400W Scooter manual available for free PDF download: Service Manual

Yamaha 2005 YP400W Service Manual

Yamaha 2005 YP400W Service Manual (390 pages)

2005-2007 years

Brand: Yamaha | Category: Motorcycle | Size: 13 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

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