Yamaha XS400 1982 Service Manual - PDF DOWNLOAD

Yamaha XS400 1982 Service Manual - PDF DOWNLOAD

FILE DETAILS:

Yamaha XS400 1982 Service Manual - PDF DOWNLOAD

Language : English
Pages : 317
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yamaha XS400 1982 Service Manual - PDF DOWNLOAD

XS400 Service Manual 1
General Information 5
Motorcycle Identification 6
Frame Serial Number 6
Engine Serial Number 6
Special Tools 8
For Tune-up 8
For Engine Service 9
For Chassis Service 14
For Electrical Components 15
Periodic Inspections and Adjustments 17
Introduction 19
Maintenance Interval Charts 19
Periodic Maintenance 20
Lubrication Intervals 21
Engine 22
Valve Clearance 22
Spark Plug 32
Crankcase Ventilation System 32
Fuel Line 32
Exhaust System 33
Carburetor Syncronisation 33
Idle Speed 35
Engine Oil and Oil Filter 36
Clutch Adjustment 41
Checking Ignition Timing 43
Compression Pressure Measurement 45
Chassis 47
Drive Chain 47
Air Filter 50
Front and Rear Brake 52
Tires and Aluminium Wheels 56
Cable Inspection and Lubrication 58
Brake and Change Pedals / Brake and Clutch Levers 59
Centerstand and Sidestand 59
Front Fork Oil Change 59
Rear Shock Absorber Adjustment 62
Steering Head Adjustment 63
Wheel Bearings 65
Fuel Cock 67
Electrical 69
Battery 69
Headlight 72
Fuse 76
Engine Overhaul 77
Engine Removal 79
Preparation for Removal 79
Seat and Fuel Tank 80
Mufflers 80
Air Cleaner Case 81
Wiring and Cables 82
Change Pedal and Drive Sprocket 83
Engine Removal 84
Engine Disassembly 85
Cylinder Head and Cylinder 85
Valve Lifters, Valves and Valve Springs 89
Piston 91
Pick-up Coil Assembly 92
Generator and Starter Motor 92
Clutch 94
Oil Pump and Shift Shaft Removal 96
Crankcase Disassembly 97
Upper Crankcase 99
Lower Crankcase100
Inspection and Repair101
Cylinder Head Cover101
Cylinder Head101
Valve, Valve Guide and Valve Seat102
Valve Spring and Lifters113
Camshafts, Cam Chain and Cam Sprockets116
Cylinder119
Piston and Piston Rings121
Piston Pin124
Crankshaft and Connecting Rod125
Balancershaft131
Oil Pump134
Primary Drive135
Clutch135
Transmission139
Starter Drives142
Crankcase143
Bearing and Oil Seals144
Engine Assembly and Adjustment145
Important Information145
Engine Assembly147
Upper crankcase147
Lower crankcase150
Crankcase assembly153
Oil pump and shift shaft156
Clutch assembly158
Starter motor160
AC Generator161
Pick-up coil assembly162
Pistons and cylinders163
Cylinder head and camshafts165
Cam chain, cam sprockets and chain tensioner170
Remounting Engine176
Carburetion179
Carburetor180
Sectional View181
Specifications182
Disassembly182
Inspection185
Adjustment187
Air Cleaner and Crankcase Ventilation System191
Chassis193
Front Wheel195
Removal195
Front Axle Inspection196
Replacing Wheel Bearings197
Installing Front Wheel198
Rear Wheel200
Removal200
Checking Brake Shoe Wear201
Brake Drum202
Brake Shoe Plate202
Rear Axle Inspection202
Replacing Wheel Bearing202
Rear Wheel Inspection203
Installing Rear Sheel203
Front Brake206
Caliper Pad Replacement206
Caliper Disassembly208
Master Cylinder Disassembly209
Brake Inspection and Repair210
Brake Reassembly213
Front Fork218
Removal and Disassembly219
Inspection221
Assembly222
Steering Head224
Adjustment225
Removal225
Inspection226
Reassembly227
Swing Arm229
Free Play Inspection230
Removal230
Inspection and Lubrication231
Assembly233
Rear Shock Absorber234
Removal234
Inspection234
Adjustment235
Drive Chain and Sprockets236
Drive Sprocket236
Driven Sprocket237
Chain Inspection238
Chain Maintenance239
Cables and Fittings240
Cable Maintenance240
Throttle Maintenance242
Electrical243
Wiring Diagram244
Electric Starting System246
Circuit Diagram246
Starter Motor247
Starter Relay Switch249
Starting Circuit Cutoff Relay250
Charging System253
Circuit Diagram253
Battery Inspection254
AC Generator254
Voltage Regulator256
Ignition System260
Circuit Diagram260
Description261
Operation261
Troubleshooting/Inspection264
Lighting System271
Circuit Diagram271
Lighting Tests and Checks272
Signal System275
Circuit Diagram275
Signal System Tests and Checks276
Self-Cancelling Flasher System278
Switches280
Battery282
Appendices285
Specifications286
General Specifications286
Maintenance Specifications288
Engine288
Chassis294
Electrical296
General Torque Specifications298
Lubrication Diagrams299
Cable Routing302
Parts Illustations308
Clutch308
Transmission309
Front Wheel310
Rear Wheel311
Front Brake (Caliper)312
Front Brake (Master Cylinder)313
Electrical Components314
Wiring Diagram316

G.B 14/03/25