Yamaha YP400T User manual

2005 - 2007

MOTORCYCLE

SERVICE MANUAL

Model : YP400T, YP400V, YP400W

5RU281972000 *5RU281972000*

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EAS00000

YP400T

SERVICE MANUAL

First edition, June 2004

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

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EAS00002 NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the scooter operator, a bystander or a person checking or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid damage

to the scooter.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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EAS00007 HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section

title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

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EAS00008

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 0to Gindicate the following.

0Serviceable with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data

Symbols Hto Min the exploded diagrams

indicate the types of lubricants and lubrication

points.

HEngine oil

IGear oil

JMolybdenum-disulfide oil

KWheel-bearing grease

LLithium-soap-based grease

MMolybdenum-disulfide grease

Symbols Nto Oin the exploded diagrams

indicate the following.

NApply locking agent (LOCTITE®)

OReplace the part

EFG

HIJ

KLM

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

FI –+

ELEC

TRBL

SHTG

EGM

BLS M

New

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GEN

INFO

CHAPTER 1

GENERAL INFORMATION

SCOOTER IDENTIFICATION..........................................................................1-1

VEHICLE IDENTIFICATION NUMBER.....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-2

OUTLINE OF THE FI SYSTEM.................................................................1-2

FI SYSTEM................................................................................................1-3

INSTRUMENT FUNCTIONS.....................................................................1-4

IMPORTANT INFORMATION .......................................................................1-10

PREPARATION FOR REMOVAL AND DISASSEMBLY.........................1-10

REPLACEMENT PARTS.........................................................................1-10

GASKETS, OIL SEALS AND O-RINGS..................................................1-10

LOCK WASHERS/PLATES AND COTTER PINS...................................1-11

BEARINGS AND OIL SEALS..................................................................1-11

CIRCLIPS................................................................................................1-11

CHECKING THE CONNECTIONS................................................................1-12

SPECIAL TOOLS..........................................................................................1-13

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1 - 1

GEN

INFO

EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1is

stamped into the frame.

EAS00018

MODEL LABEL

The model label 1is affixed inside the storage

box. Record the information on this label in the

space provided. This information will be

needed when ordering spare parts.

SCOOTER IDENTIFICATION

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1 - 2

GEN

INFO

FEATURES

EAS00896

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-

mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-

ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the

combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet

used in the respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating

conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that

meter the fuel through the use of jets have been provided with various auxiliary devices, so that an

optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-

ditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases

increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-

ner. To accommodate this need, this model has adopted an electronically controlled fuel injection

(FI) system, in place of the conventional carburetor system. This system can achieve an optimum

air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel

injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine

response, better fuel economy, and reduced exhaust emissions.

1ECU

2Fuel injection system

relay

3Engine trouble warn-

ing light

4Lean angle cut-off

switch

5Fuel hose

6Ignition coil

7Fuel injector

8Intake air pressure

sensor

9Throttle position sen-

sor

0ISC (idle speed con-

trol) valve

AIntake air temperature

sensor

BBattery

CAir filter case

DCatalytic converter

ECrankshaft position

sensor

FCoolant temperature

sensor

GSpark plug

HFuel tank

IFuel pump

780

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1 - 3

GEN

INFO

FEATURES

EAS00897

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains

the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm2, 35.6 psi). Accord-

ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,

causing the fuel to be injected into the intake manifold only during the time the passage remains

open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the

greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector

is energized (injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from

the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake tempera-

ture sensor and coolant temperature sensor enable the ECU to determine the injection duration.

The injection timing is determined through the signals from the crankshaft position sensor. As a

result, the volume of fuel that is required by the engine can be supplied at all times in accordance

with the driving conditions.

1Fuel pump

2Fuel injector

3Ignition coil

4ECU

5Catalytic converter

6Coolant temperature

sensor

7Crankshaft position

sensor

8Intake air pressure

sensor

9Throttle body

0Intake air temperature

sensor

AAir filter case

BThrottle position sen-

sor

CISC (idle speed con-

trol) valve

ÈFuel system

ÉAir system

ÊControl system

Illustration is for reference only.

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1 - 4

GEN

INFO

FEATURES

INSTRUMENT FUNCTIONS

Multifunction display

WARNING

Be sure to stop the vehicle before making any

setting changes to the multifunction display.

1Clock/ambient temperature display

2Coolant temperature meter

3Fuel meter

4Odometer/tripmeters

5“SELECT” button

6“RESET” button

1V-belt replacement indicator “V-BELT”

2Fuel level warning symbol “ ”

3Coolant temperature symbol “ ”

4Oil change indicator “OIL”

The multifunction display is equipped with the

following:

• a fuel meter

• a coolant temperature meter

• an odometer (which shows the total dis-

tance traveled)

• two tripmeters (which show the distance

traveled since they were last set to zero)

• a fuel reserve tripmeter (which shows the

distance traveled since the bottom segment

of the fuel meter and fuel level warning

symbol started flashing)

• a self-diagnosis device

•aclock

• an ambient temperature display

• an oil change indicator

• a V-belt replacement indicator

NOTE:

• Be sure to turn the key to “ON” before using

the “SELECT” and “RESET” buttons.

• When the key is turned to “ON”, all of the dis-

play segments of the multifunction display

will appear one after the other and then dis-

appear, in order to test the electrical circuit.

CAUTION:

If bars 1appear where the odometer and

tripmeters are normally displayed, the

multi-function display is malfunctioning.

Replace the entire multi-function display.

3412

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