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2007 YP400T
Yamaha 2007 YP400T Manuals
Manuals and User Guides for Yamaha 2007 YP400T. We have
1
Yamaha 2007 YP400T manual available for free PDF download: Service Manual
Yamaha 2007 YP400T Service Manual (390 pages)
2005-2007 years
Brand:
Yamaha
| Category:
Motorcycle
| Size: 13.87 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
Passenger Seat and Side Covers
77
Rider Seat and Storage Box
78
Side Cover Mouldings and Footrest Boards
80
Front Cowling
81
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 Brake Pads
144
Rear Brake Pads
145
Replacing the Front Brake Pads
146
Replacing the Rear Brake Pads
148
Front Brake Master Cylinder
151
Rear Brake Master Cylinder
154
Disassembling the Rear Brake Master Cylinder
156
Checking the Front and Rear Brake Master Cylinders
158
Assembling and Installing the Front Brake Master Cylinder
159
Assembling and Installing the Rear Brake Master Cylinder
161
Front Brake Caliper
164
Rear Brake Caliper
166
Disassembling the Rear Brake Caliper
168
Checking the Front and Rear Brake Calipers
170
Assembling and Installing the Front Brake Caliper
172
Assembling and Installing the Rear Brake Caliper
174
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
Removing the Rear Shock Absorber Assemblies
200
Checking the Rear Shock Absorber Assemblies
200
Installing the Rear Shock Absorber Assemblies
200
Removing the Swingarm
201
Checking the Swingarm
201
Installing the Swingarm
202
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
Removing the Cylinder Head
223
Checking the Cylinder Head
223
Checking the Timing Chain Guide (Exhaust Side)
224
Installing the Cylinder Head
224
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
Crankshaft Assembly and Balancer Shaft Assembly
263
Crankcase Bearings
265
Disassembling the Crankcase
266
Removing the Crankshaft Journal Bearings
266
Checking the Crankshaft and Connecting Rod
267
Checking the Balancer Shaft Assembly
270
Checking the Crankcase
270
Checking the Timing Chain and Timing Chain Guide (Intake Side)
271
Checking the Oil Pump Gears and Shafts
271
Checking the Relief Valve
271
Checking the Bearings and Oil Seals
271
Checking the Circlips and Washers
272
Installing the Crankshaft Journal Bearings
272
Installing the Crankshaft Assembly and Balancer Shaft Assembly
273
Assembling the Crankcase
273
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
Types of Bulbs
336
Checking the Condition of the Bulbs
337
Checking the Condition of the Bulb Sockets
338
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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