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2004 YP400
Yamaha 2004 YP400 Manuals
Manuals and User Guides for Yamaha 2004 YP400. We have
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Yamaha 2004 YP400 manual available for free PDF download: 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
Chassis Specifications
40
Electrical Specifications
44
Conversion Table
47
General Tightening Torque Specifications
47
Tightening Torques
48
Engine Tightening Torques
48
Chassis Tightening Torques
51
Lubrication Points and Lubricant Types
53
Engine Lubrication Points and Lubricant Types
53
Chassis Lubrication Points and Lubricant Types
55
Cooling System Diagrams
56
Cable Routing
58
Chapter 3 Periodic Checks and Adjustments
78
Introduction
80
Periodic Maintenance and Lubrication Chart
80
Cowling and Covers
82
Passenger Seat and Side Covers
82
Rider Seat and Storage Box
83
Side Cover Mouldings and Footrest Boards
85
Front Cowling
86
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 Brake Pads
151
Rear Brake Pads
152
Replacing the Front Brake Pads
153
Replacing the Rear Brake Pads
155
Front Brake Master Cylinder
158
Rear Brake Master Cylinder
161
Disassembling the Rear Brake Master Cylinder
163
Checking the Front and Rear Brake Master Cylinders
165
Assembling and Installing the Front Brake Master Cylinder
166
Assembling and Installing the Rear Brake Master Cylinder
168
Front Brake Caliper
171
Rear Brake Caliper
173
Disassembling the Rear Brake Caliper
175
Checking the Front and Rear Brake Calipers
177
Assembling and Installing the Front Brake Caliper
179
Assembling and Installing the Rear Brake Caliper
181
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
Removing the Rear Shock Absorber Assemblies
207
Checking the Rear Shock Absorber Assemblies
207
Installing the Rear Shock Absorber Assemblies
207
Removing the Swingarm
208
Checking the Swingarm
208
Installing the Swingarm
209
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
Removing the Cylinder Head
232
Checking the Cylinder Head
232
Checking the Timing Chain Guide (Exhaust Side)
233
Installing the Cylinder Head
233
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
Crankshaft Assembly and Balancer Shaft Assembly
272
Crankcase Bearings
274
Disassembling the Crankcase
275
Removing the Crankshaft Journal Bearings
275
Checking the Crankshaft and Connecting Rod
276
Checking the Balancer Shaft Assembly
279
Checking the Crankcase
279
Checking the Timing Chain and Timing Chain Guide (Intake Side)
279
Checking the Oil Pump Gears and Shafts
280
Checking the Relief Valve
280
Checking the Bearings and Oil Seals
280
Checking the Circlips and Washers
280
Installing the Crankshaft Journal Bearings
281
Installing the Crankshaft Assembly and Balancer Shaft Assembly
281
Assembling the Crankcase
282
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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