Yamaha YP400 - Service Manual - Taller - Reparation - Reparaturanleitung - Officina

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YAMAHA YP400 - MANUAL DE TALLER - SERVICE MANUAL

- English, French, German, Italian and Spanish Service Manual, in PDF format, to motorcycles Yamaha YP400

CONTENTS:

GENERAL INFORMATION
- SCOOTER IDENTIFICATION
Vehicle identification number
Model label
- CHARACTERISTICS
Synopsis of the fuel injection system (fi)
fi system
Instrument function
- IMPORTANT INFORMATION
Preparation for removal and disassembly
Spare parts
Gaskets, oil seals and O-rings
Lock washers/lock plates and
split pins
Bearings and oil seals
elastic rings
- CHECKING THE CONNECTIONS
- SPECIAL TOOLS

SPECIFICATIONS
- GENERAL SPECIFICATIONS
- ENGINE SPECIFICATIONS
- CHASSIS SPECIFICATIONS
- ELECTRICAL SYSTEM SPECIFICATIONS
- CONVERSION TABLE
- SPECIFICATIONS OF GENERAL TIGHTENING TORQUES
- TIGHTENING TORQUES
Engine tightening torques
Chassis tightening torques
- GREASE POINTS AND TYPES OF LUBRICANT
Engine grease points and types of lubricant
Chassis grease points and types of lubricant
- COOLING SYSTEM DIAGRAMS
- CABLE ARRANGEMENT

PERIODIC CHECKS AND ADJUSTMENTS
- INTRODUCTION
- PERIODIC MAINTENANCE AND GREASE SCHEME
- FAIRING AND COVERS
Passenger seat and side covers
Driver's seat and storage compartment
Molded parts of the side covers and
The footrests
Front fairing
- AIR FILTER HOUSINGS
- ENGINE
Valve clearance adjustment
Exhaust gas volume adjustment
Checking engine idle
Throttle cable play adjustment
Checking the spark plug
Checking the ignition timing
Compression pressure measurement
Checking the engine oil level
Engine oil change


Changing the gearbox oil
Replacing air filter elements
Cleaning the air filter element
V-belt housing
Checking the body gasket
Throttle and intake manifold

Checking the fuel pipe
Checking the breather tubes
Checking the exhaust system
Checking the coolant level
Checking the cooling system
Coolant change
- CHASSIS
Lock Handle Cable Adjustment
Back brake
Checking the brake fluid level
Checking the brake pads
Front and rear
Checking the brake pipes
Front and rear
Bleeding the hydraulic brake system
Checking and adjusting the steering column
Checking the front fork
Checking the tires
Checking the wheels
Checking and lubricating the cables
Lubricating the levers
Side stand lubrication
Lubricating the center stand
- ELECTRIC SYSTEM
Checking and charging the battery
Checking the fuses
Changing the headlight bulbs
Headlight beam adjustment

CHASSIS
- FRONT WHEEL AND BRAKE DISC
Front wheel removal
Checking the front wheel
Checking the brake discs
Front wheel assembly
Static front wheel balancing
- REAR WHEEL AND BRAKE DISC
Rear wheel removal
Checking the rear wheel
Static rear wheel balancing
- FRONT AND REAR BRAKES
Front brake pads
rear brake pads
Changing the front brake pads
Changing the rear brake pads
Front brake master cylinder
rear brake master cylinder
Disassemble the front brake master cylinder
Disassemble the rear brake master cylinder
Checking the brake master cylinders
Front and rear
Assemble and install the front brake master cylinder
Assemble and install the rear brake master cylinder
front brake caliper
rear brake caliper
Disassemble the front brake caliper
Disassemble the rear brake caliper
Checking the brake calipers
Front and rear
Assemble and install the front brake caliper
Assemble and install the rear brake caliper
- FRONT FORK
Disassembly of the front fork bars
Disassemble the front fork bars
Checking the fork legs
Lead
Assemble the front fork bars
Installing the front fork legs
- HANDLEBAR
Handlebar disassembly
Checking the handlebar
Handlebar assembly
- STEERING COLUMN
Bottom Bracket
Bottom Bracket Disassembly
Checking the steering column
Steering column installation
- REAR SHOCK ABSORBER AND ARM ASSEMBLY
- OSCILLATING
Disassembly of the shock absorber assemblies
Rears
Checking the sets
Rear shock absorbers
Installing the shock absorber assemblies
Rears
Removing the swing arm
Checking the swing arm
Swing Arm Installation

ENGINE
- ENGINE DISASSEMBLY
Cables, pipes, exhaust pipe and silencer
Engine
Engine installation
- CAMSHAFTS
cylinder head cover
camshafts
Disassembly of the camshafts
Checking the camshafts
Checking the camshaft sprockets
Checking the decompression system
Checking the chain tensioner
Of distribution
Installing the camshafts
- HEAD
Cylinder head disassembly
Checking the cylinder head
Checking the chain guide
Distribution (exhaust side)
Cylinder head installation
- VALVES AND VALVE SPRINGS
Valve disassembly
Checking valves and valve guides
Checking valve seats
Checking the valve springs
Checking the valve lifters
Valve installation
- CYLINDER AND PISTON
Piston disassembly
Checking the cylinder and piston
Checking the piston rings
Checking the piston pin
Piston and cylinder installation
- BELT TRANSMISSION
V-belt housing cover
V-belt and primary/secondary disc
Secondary disk
Removing the primary disk
Removing the secondary disc and belt
Trapezoidal
Disassemble the secondary disk
Checking the V-belt
Checking the air ducts of the
V-belt housing
Checking the primary disk
Checking the primary disc counterweights
Checking the secondary disk
Checking the clutch shoes
Assemble the primary disk
Arm the secondary disk
Installing secondary disc, belt
Trapezoidal and primary disc
- STARTER MOTOR AND ALTERNATOR CLUTCH
Alternator rotor cover and stator coil
Starter and alternator clutch
Disassembly of the alternator
Checking the starter clutch

Installing the starter clutch
Alternator Installation
- OIL PUMP
Checking the oil pump
Checking the timing chain
oil pump
Assemble the oil pump
Oil pump installation
- CRANKSHAFT
Crankshaft assembly and balancer shaft assembly
Crankcase bearings
Disassemble the crankcase
Disassembly of the crankshaft bearings
Checking the crankshaft and connecting rod
Checking the balancer shaft assembly
Checking the crankcase
Checking the timing chain and guide
Timing chain (intake side)
Checking the gears and shafts
Oil pump
Checking the safety valve
Checking bearings and oil seals
Checking the snap rings and washers
Installing the crankshaft bearings
Installing the crankshaft assembly and assembly
Of the compensating shaft
Assemble the crankcase
- GEARBOX
Checking the gearbox
Installing the gear oil seal
Primary driver

REFRIGERATION SYSTEM
- RADIATOR
Checking the radiator
Radiator installation
- THERMOSTAT
Checking the thermostat
Thermostat installation
- WATER PUMP AND OIL COOLER
Checking the water pump
Checking the oil cooler
Assemble the water pump

FUEL INJECTION SYSTEM
- FUEL INJECTION SYSTEM
Electric diagram

ECU self-diagnosis function
Function control with instructions
Alternatives (fail-safe action)
Failsafe Action Chart
Troubleshooting chart
Diagnostic function
Troubleshooting details
- THROTTLE BODY AND FUEL INJECTOR
Throttle body and fuel injector
fuel tube
Fuel tank
Disassembly of the fuel pipe
Disassembly of the fuel pump
Checking the fuel injector
Checking the throttle body
Fuel pump assembly
Subframe Installation
Fuel line installation
Checking pump operation
Fuel and pressure regulator
Checking the position sensor
Of the accelerator
Checking the control valve
Idling (isc)
- AIR INDUCTION SYSTEM
Air injection
Air shut-off valve
Air induction system diagrams
Air shut-off valve and system tubes
air induction
Checking the air induction system

ELECTRIC SYSTEM
- ELECTRIC COMPONENTS
- CHECKING THE CONTINUITY OF THE SWITCHES
- CHECKING THE SWITCHES
- CHECKING BULBS AND CAPS
Types of bulbs
Checking the condition of the bulbs
Checking the condition of the bushings
Checking the LEDs
- IGNITION SYSTEM
Circuit diagram
Troubleshooting
- ELECTRICAL STARTING SYSTEM
Circuit diagram
Circuit cutting system operation
Boot
Troubleshooting
- STARTER MOTOR
Checking the starter motor
Assemble the starter motor
- CHARGING SYSTEM
Circuit diagram
Troubleshooting
- LIGHTING SYSTEM
Circuit diagram
Troubleshooting
Checking the lighting system
- SIGNALING SYSTEM
Circuit diagram
Troubleshooting
Checking the signaling system
- REFRIGERATION SYSTEM
Circuit diagram
Troubleshooting
- IMMOBILIZER SYSTEM
System diagram
Circuit diagram
General information
Key code registration
Self-diagnosis fault codes
Troubleshooting
Checking the immobilizer system
Key registration requirements for replacement
of parts

TROUBLESHOOTING
- STARTING FAILURE/BRUSH START
Engine
Fuel system
Electric systems
- INCORRECT IDLE
Engine
Fuel system
Electric systems
- REDUCED PERFORMANCES AT MEDIUM AND HIGH SPEED
Engine
Fuel system
- BROKEN CLUTCH
The engine runs but the scooter does not move
The clutch slips
Poor starting performance
Low speed performance
- OVERHEATING
Engine
Refrigeration system
Fuel system
Chassis
Electric systems
- EXCESS COOLING
Refrigeration system
- INSUFFICIENT BRAKING
- FRONT FORK BARS DAMAGED
Oil leak
Malfunction
- UNSTABLE BEHAVIOR
- FAULTY LIGHTING OR SIGNALING SYSTEM
The headlight does not turn on
Headlight bulb burned out
Taillight/brake light does not come on
Burnt taillight/brake light bulb
The turn signals do not turn on
Turn signals flash slowly
The turn signal stays on
Turn signal blinks too fast
The horn does not sound

ELECTRICAL DIAGRAM OF THE YP400 (S)