Yamaha YP400T, YP400V, YP400W, 2005 YP400T, 2005 YP400V Service Manual

2005 - 2007

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SERVICE MANUAL
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Model : YP400T, YP400V, YP400W

5RU281972000 *5RU281972000*

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		YP400T
	SERVICE MANUAL
	©2004 by Yamaha Motor Co., Ltd.
	First edition, June 2004
	All rights reserved.
	Any reproduction or unauthorized use
	without the written permission of
	Yamaha Motor Co., Ltd.
	is expressly prohibited.

.net .ScooterTime www

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NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers 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 dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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			The Safety Al rt Symbol means ATTENTION! BECOME ALERT! YOUR
			SAFETY IS INVOLVED!
	WARNING		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.
	CAUTION:		A CAUTION indicates special precautions that must be taken to avoid damage
			to the scooter.
NOTE:			A NOTE provides key information to make procedures easier or clearer.

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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.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter.

Refer to “SYMBOLS”.

2 Each 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.

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

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

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

disassembly step.	.
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6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, p oviding the order of jobs, names of parts, notes in jobs, etc.

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

tially.
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1

2

	GEN	SPEC
	INFO
	3	4
	CHK	CHAS
	ADJ
	5	6
	ENG	COOL
	7	8
	FI	ELEC – +
	9	0

TRBL

SHTG

A B

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SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

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Symbols 0 to G indicate the following.
0 Servic able with engine mounted
A Filling fluid
B Lubricant
C Spe ial tool
.
D Tightening torque
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E Wear limit, clearance
F Engine speed
G Electrical data

H I J

E G M

K L M

B

LS

M

N O

New

LT

Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points.

H Engine oil I Gear oil

JMolybdenum-disulfide oil

KWheel-bearing grease

LLithium-soap-based grease

MMolybdenum-disulfide grease

Symbols N to O in the exploded diagrams indicate the following.

N Apply locking agent (LOCTITE®) O Replace the part

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				. net		1-10
LOCK WASHERS/PLATES AND COTTER PINS ...................................						1-11
BEARINGS AND OIL SEALS ..................................................................						1-11
CIRCLIPS ................................................................................................						1-11
CHECKING THE CONNECTIONS ............			..............................................1-12
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SPECIAL TOOLS ..........................................................................................						1-13
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SCOOTER IDENTIFICATION INFO

1

1

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GENERAL INFORMATION

SCOOTER IDENTIFICATION

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VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the frame.

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MODEL LABEL
The model label 1 is affixed inside the storage
box. Record the information on this label in the
space provided. This information will be
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needed when ordering spare parts.
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1 - 1

FEATURES

EAS00896

FEATURES

OUTLINE OF THE FI SYSTEM

GEN INFO

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. 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 conditions 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 manner. To accommodate this need, this model has adopted an electronicallynetcontrolled fuel injection (FI) system, in place of the conventional carburetor system. This syst .m 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 pr cise fuel supply, improved engine

response, better fuel economy, and reduced exhaust emissi						ns.
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	H	F		D	C
	I	G	E
1 ECU	5 Fuel hose	0 ISC (idle speed con-			E Crankshaft position
2 Fuel injection system	6 Ignition coil	trol) valve			sensor
relay	7 Fuel injector	A Intake air temperature			F Coolant temperature
3 Engine trouble warn-	8 Intake air pressure	sensor			sensor
ing light	sensor	B Battery			G Spark plug
4 Lean angle cut-off	9 Throttle position sen-	C Air filter case			H Fuel tank
switch	sor	D Catalytic converter			I Fuel pump

1 - 2

FEATURES

EAS00897

FI SYSTEM

GEN INFO

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). Accordingly, 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 temperature 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

						net		imes in accordance
result, the volume of fuel that is required by the engine can be supplied at all
with the driving conditions.						.
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Illustration is for reference only.

1 Fuel pump	7 Crankshaft position	A Air filter case	È Fuel system
2 Fuel injector	sensor	B Throttle position sen-	É Air system
3 Ignition coil	8 Intake air pressure	sor	Ê Control system
4 ECU	sensor	C ISC (idle speed con-
5 Catalytic converter	9 Throttle body	trol) valve
6 Coolant temperature	0 Intake air temperature
sensor	sensor

1 - 3

GEN

FEATURES INFO

1

2

3

4

5

6

1

2

3

4

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INSTRUMENT FUNCTIONS

Multifunction display

WARNING

Be sure to stop the vehicle before making any setting changes to the multifunction display.

1 Clock/ambient temperature display

2 Coolant temperature meter

3 Fuel meter

4Odometer/tripmeters

5“SELECT” button

6“RESET” button

1 V-belt replacement indicator “V-BELT”
2 Fuel level warning symbol “						”
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3 Coolant temperature symbol “									”
		.
4 Oil change indicator “OIL”
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The multifunction display is equipped with the
following:
	• a fuel meter
	• a coolant temperature meter
	• an	d meter (which shows							the total dis-
	tan	e traveled)
.
www	• 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

• a clock

• 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 display 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 1 appear where the odometer and tripmeters are normally displayed, the multi-function display is malfunctioning.

Replace the entire multi-function display.

1

1 - 4

1

FEATURES

GEN

INFO

Odometer and tripmeter modes

Pushing the “SELECT” button switches the

display between the odometer mode “ODO”

and the tripmeter modes “TRIP” in the follow-

ing order:

ODO → TRIP (top) → TRIP (bottom) → ODO

When approximately 2.8 L (0.62 Imp gal,

0.74 US gal) of fuel remains in the fuel tank, the

bottom segment of the fuel meter and fuel level

warning symbol will start flashing, and the dis-

play will automatically change to the fuel reserve

tripmeter mode “TRIP F” and start counting the

distance traveled from that point. In that case,

pushing the “SELECT” button switches the dis-

net

play between the various

ripmeter and odome-

ter modes in the followi g order:

.

→ TRIP (bottom) →

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TRIP F → TRIP (top)

ODO → TRIP F

1 Fuel rese ve tripmeter

To reset a t ipmeter, select it by pushing the

“SELECT” button, until “TRIP” or “TRIP F”

begins flashing (“TRIP” or “TRIP F” will only

.

flash for five seconds). While “TRIP” or “TRIP F”

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is flashing, push the “RESET” button for at least

one second. If you do not reset the fuel reserve

from

tripmeter manually, it will reset itself automati-

cally and the display will return to the prior

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mode after refueling and traveling 5 km (3 mi).

NOTE:

The display cannot be changed back to “TRIP

F” after pushing the “RESET” button.

Fuel meter

With the key in the “ON” position, the fuel

meter indicates the amount of fuel in the fuel

tank. The display segments of the fuel meter

disappear towards “E” (Empty) as the fuel level

decreases. When the fuel level reaches the

bottom segment near “E”, the fuel level warn-

ing symbol and the bottom segment will flash.

Refuel as soon as possible.

CAUTION:

If the fuel level is not displayed and the fuel

level warning symbol, triangular mark, “E”

line, and “F” line flash in the fuel meter, the

fuel level monitoring system is malfunc-

tioning. Check the fuel sender and the elec-

trical circuit.

1 - 5

GEN

FEATURES INFO

Coolant temperature meter

With the key in the “ON” position, the coolant temperature meter indicates the temperature of the coolant. The coolant temperature varies with changes in the weather and engine load. If the top segment and coolant temperature symbol flash, stop the vehicle and let the engine cool.

CAUTION:

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Do not operate the engine if it is overheated.

Oil change indicator “OIL”

This indicator flashesnetat he initial 1,000 km (600 mi), then at 5,000 km (3,000 mi) and

change indicator. Refer to “To reset the oil change indicator”. If the engine oil is changed before the oil change indicator comes on (i.e.

every 5,000 km (3,000. mi) thereafter to indicateScooterTimethat the engine oil should be changed. After changing the engine oil, reset the oil

before the periodic oil change interval has . wwwbeen reached), the indicator must be reset

after the oil change for the next periodic oil change to be indicated at the correct time. The electrical circuit of the indicator can be checked according to the following procedure.

1.Set the engine stop switch to “ ” and turn the key to “ON”.

2.Check that the indicator comes on for a few seconds and then goes off.

3.If the indicator does not come on, check the electrical circuit. Refer to “SIGNALING SYSTEM” in chapter 8.

NOTE:

The oil change indicator may flash when the engine is revved with the scooter on the centerstand, but this does not indicate a malfunction.

1 - 6

GEN

FEATURES INFO

1

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1

To reset the oil change indicator

1.Turn the key to “ON”.

2.Hold the reset button pushed for two to

eight seconds.

1 Reset button “OIL CHANGE”

3.Release the reset button, and the oil change indicator will go off.

NOTE:

If the engine oil is changed before the oil change indicator comes on (i.e. before the periodic oil change interval has been reached), the indicator must be reset after the oil change

	for the next periodic oil change to be indicated
	at the correct time. To reset the oil change
	indicator before the periodic oil change interval
	has been reached, follow the above proce-
.
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	dure, but note that thenetindicator will come on
	for 1.4 seconds after releasing the reset but-
	ton, otherwise repeat the procedure.
	V-belt replacement indicator “V-BELT”
	This indicator flashes	every	20,000	km
.		V-belt	needs to	be
	(12,500 mi) when the
www
	replaced.

The electrical circuit of the indicator can be checked according to the following procedure.

1.Turn the key to “ON” and make sure that the engine stop switch is set to “ ”.

2.If the indicator does not come on, check the electrical circuit. Refer to “SIGNALING SYSTEM” in chapter 8.

To reset the V-belt replacement indicator

1.Turn the key to “ON” and make sure that the engine stop switch is set to “ON”.

2.Disconnect the V-belt replacement reset coupler 1 for two to ten seconds.

3.And then, connect the V-belt replacement reset coupler, the V-belt replacement indicator will come on for 1.4 seconds.

And the V-belt replacement indicator will go

off.

NOTE:

If the V-belt is replaced before the V-belt replacement indicator comes on (i.e. before the V-belt replacement interval has been reached), the indicator must be reset after the V-belt replacement for the next periodic V-belt replacement to be indicated at the correct time.

1 - 7

GEN

FEATURES INFO

Self-diagnosis device

This model is equipped with a self-diagnosis device for various electrical circuits.

If any of those circuits are defective, the multifunction display will indicate a two-digit error code (e.g., 12, 13, 14).

If the multifunction display indicates an error code, note the code number, and then check the vehicle. Refer to “FUEL INJECTION SYSTEM” in chapter 7.

CAUTION:

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If the multifunction display indicates an
error code, the vehicle should be checked
as soon as possible in order to avoid
engine damage.		net
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Clock m de
To set the clock:
.
1 Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push
www the “RESET” button to set the hours.

3.Push the “SELECT” button, and the minute digits will start flashing.

4.Push the “RESET” button to set the minutes.

5.Push the “SELECT” button and then release it to start the clock. Pushing the “RESET” button for at least two seconds switches the clock display to the ambient

temperature display.

1 - 8

GEN

FEATURES INFO

Ambient temperature display

This display shows the ambient temperature from –10 °C to 50 °C in 1 °C increments. The temperature displayed may vary from the ambient temperature. Pushing the “RESET” button for at least two seconds switches the ambient temperature display to the clock display.

•When the ambient temperature falls below

–10.0 °C, “–10.0 °C” is displayed.

•When the ambient temperature climbs above 50.0 °C, “50.0” is displayed.

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NOTE:

• If “– – °C” is displayed or “50.0” flashes while the ambient temperaturenet is between –10.0 °C

• The accu acy of the temperature reading may be aff cted when riding slowly (approximately under 20 km/h) or when stopped at

and 50.0 °C, there.is a problem with the elec- ScooterTimetrical circuit. Ch ck or repair the electric circuit or replace the thermistor.

traffic signals, railroad crossings, etc. . www

1 - 9

GEN

IMPORTANT INFORMATION INFO

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1.Before removal and disassembly, remove all dirt, mud, dust and foreign material.

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	2.	Use only the proper tools and cleaning
		equipment.
		Refer to “SPECIAL TOOLS”.
	3.	When disassembling, always keep mated
			net
		parts together. This includes gears, cylin-
		.
		ders, pistons and other parts that have been
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		“mated” through normal wear. Mated parts
		must always be reused or replaced as an
		assembly.
	4.	During disassembly, clean all of the parts
		and place them in trays in the order of dis-
		assembly. This will speed up assembly and
	.
	www	allow for the correct installation of all parts.
		Keep all parts away from any source of fire.
	5.

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REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

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GASKETS, OIL SEALS AND O-RINGS

1.When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2.During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

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GEN

IMPORTANT INFORMATION INFO

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LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

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BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When

installing oil seals, lubricate the oil seal lips
	net
with a light coat of lithium-soap-based grease.
.
Oil bearings liberally when installing, if appro-
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priate.

1 Oil seal

CAUTION:

Do n t spin the bearing with compressed

air because this will damage the bearing . surfaces.

www2 Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.

4 Shaft

1 - 11

GEN

CHECKING THE CONNECTIONS INFO

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1.Disconnect:

•lead

•coupler

•connector

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2. Check:
• lead
• coupler
• connector			net
Moisture → Dry with an air blower.
		.
Rust/stains → Co ect and disconnect sev-
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eral times.
3. Check:
• all onnections
.
Loose connection → Connect properly.
wwwup.
NOTE:
If the pin 1 on the terminal is flattened, bend it

4.Connect:

•lead

•coupler

•connector

NOTE:

Make sure all connections are tight.

5.Check:

•continuity

(with the pocket tester)

Pocket tester 90890-03112, YU-03112-C

NOTE:

•If there is no continuity, clean the terminals.

•When checking the wire harness, perform steps (1) to (3).

•As a quick remedy, use a contact revitalizer

available at most part stores.

1 - 12

SPECIAL TOOLS

EAS00027

SPECIAL TOOLS

GEN INFO

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.

When placing an order, refer to the list provided below to avoid any mistakes.

NOTE:

•For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

•For others, use part number starting with “90890-”.

Tool No.	Tool name/Function					Illustration
	Rotor holding tool
90890-01235					.
YU-01235						net
	This tool is used to hold the primary fixed
	sheave and clutch shoe assembly.
	Ring nut wrench
90890-01268			.
YU-01268
				ScooterTime
	This tool is used to loosen or tighten the
	steering ring nuts.
	Piston pin puller set		www
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90890-01304
YU-01304
	This tool is us d to remove the piston
	pins.
Radiator cap tester	Radiator cap tester
90890-01325	Radiator cap tester adapter
YU-24460-01
Radiator cap tester
adapter	These tools are used to check the cooling
90890-01352
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YU-33984	system.
	T-handle
T-handle	Damper rod holder
90890-01326
Damper rod holder	These tools are used to hold the damper
90890-01460	rod when removing or installing the
	damper rod.
	Locknut wrench
90890-01348
YM-01348
	This tool is used to remove or install the
	clutch shoe assembly nut.

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		SPECIAL TOOLS					GEN
							INFO
Tool No.	Tool name/Function				Illustration
Flywheel puller	Flywheel puller
	Flywheel puller attachment
90890-01362
Flywheel puller
attachment
90890-04089	This tool is used to remove the generator
YM-33282
	rotor.
Fork seal driver weight	Fork seal driver weight
90890-01367	Fork seal driver attachment (41 mm)
YM-A9409-7
Fork seal driver	These tools are used to install the oil
attachment
	seal, dust seal, and the outer tube bush-
90890-01381
YM-A5142-2	ing of a front fork leg.
	Oil seal guide				net
90890-01396			ScooterTime
	This tool is used for protecting the oil seal			.
	lip when installing the secondary sliding
	sheave.
	Steering nut wrench
90890-01403
YU-A9472		.
	This tool is used to loosen or tighten the
	steering ring nuts.
Pivot shaft wrench	Pivot shaft wrench	www
	Pivot shaft wrench adapter
90890-01471
YM-01471
Pivot shaft wrench	Downloadedrotor and clutch housing.
adapter	These tools are usedfromto tighten the sub-
90890-01476	frame adjusting bolt.
	Sheave h lder
90890-01701
YS-01880-A
	This tool is used to hold the generator
Compression gauge	Compression gauge
90890-03081	Adapter (compression gauge)
YU-33223
Adapter (compres-
sion gauge)	These tools are used to measure engine
90890-04082
	compression.
	Pocket tester
90890-03112
YU-03112-C
	This tool is used to check the electrical
	system.

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	SPECIAL TOOLS			GEN
				INFO
Tool No.	Tool name/Function	Illustration
	Timing light
90890-03141
YU-03141
	This tool is used to check the ignition tim-
	ing.
	Pressure gauge
90890-03153
YU-03153
	This tool is used to measure fuel pres-
	sure.

	Adapter			net
90890-03181
			.
YM-03181
			ScooterTime
90890-01243
	This tool is used to measure fuel pres-
	sure.
Valve spring compres- Valve spring compressor
sor	Valve spring compressor attachment
90890-04019
YM-04019
Valve spring compres-		.
sor attachment
	These tools are used to remove or install
YM-01253-1	the valve assemblies.
Middle driven shaft	Middle driven shaft bearing driver
bearing driver	Mechanical seal installer	www
90890-04058
YM-04058
Mechanical seal	Downloadedvalve guides.
installer	These tools are usedfromto install the water
90890-04145	pump seal.
YM-04145
	Valve guide remover (5 mm)
90890-04097
YM-04097
	This tool is used to remove or install the

Valve guide installer (5 mm)

90890-04098 YM-04098

This tool is used to install the valve guides.

Valve guide reamer (5 mm)

90890-04099 YM-04099

This tool is used to rebore the new valve guides.

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			SPECIAL TOOLS					GEN
								INFO
Tool No.		Tool name/Function				Illustration
		Valve lapper
90890-04101
		This tool is needed to remove and install
		the valve lifters.
Sheave spring com-		Sheave spring compressor
pressor		Sheave fixed block
90890-04134
YM-04134		This tool is used to hold the compression
Sheave fixed block
		spring when removing or installing the
90890-04135
YM-04135		clutch shoe assembly nut.
		Plane bearing installer/remover				net
90890-04146
					.
YM-04146
				ScooterTime
		This tool is used to install or remove the
		crankshaft journal bearings.
		Ignition checker
90890-06754
YM-34487			.
		This tool is used to check the ignition sys-
		tem components.
ACC-11001-05-01		Yamaha bond No. 1215
		This bond is used tofromseal two mating sur-
Bond		Sealant (Quick Gasket®)	www
90890-85505
Sealant		Downloaded
		faces (e.g., crankcase mating surfaces).

1 - 16

SPEC

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................						2-1
ENGINE SPECIFICATIONS ...........................................................................						2-2
CHASSIS SPECIFICATIONS	........................................................................					2-10
ELECTRICAL SPECIFICATIONS .................................................................					net	2-14
CONVERSION TABLE						2-17
					.
				ScooterTime		2-17
GENERAL TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUES ..............................................................................						2-18
ENGINE TIGHTENING TORQUES.........................................................						2-18
CHASSIS TIGHTENING TORQUES.......................................................						2-21
			.
		www				2-23
LUBRICATION POINTS AND LUBRICANT TYPES ....................................
ENGINE LUBRICATION POINTS AND LUBRICANT ................TYPES						2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT .............TYPES						2-25
	from					2-26
COOLING SYSTEM DIAGRAMS ..................................................................
Downloaded						2-28
CABLE ROUTING .........................................................................................

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item				Standard
Model code		5RU4 (USA)
		5RUC (CDN)
Dimensions
Overall length		2,230 mm (87.8 in)
Overall width		780 mm (30.7 in)
Overall height		1,380 mm (54.3 in)
Seat height		750 mm (29.5 in)
Wheelbase		1,565 mm (61.6 in)
Minimum ground clearance		120 mm (4.72 in)				net
Minimum turning radius		2,600 mm (102.4 in)
Weight					.
Wet (with oil and a full fuel tank)				ScooterTime
		212 kg (467 lb)
Maximum load (total of cargo, rider,		196 kg (432 lb)
passenger, and accessories)
			.
	from		www
Downloaded

Limit

----

----

----

----

----

----

----

----

----

----

----

2 - 1

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS

Item

Standard

Limit

Engine

Engine type

Liquid-cooled, 4-stroke, DOHC

----

Displacement

394.9 cm3 (24.10 cu.in)

----

Cylinder arrangement

Forward-inclined single cylinder

----

Bore × stroke

83.0 × 73.0 mm (3.27 × 2.87 in)

----

Compression ratio

10.6 : 1

----

Engine idling speed

1,300 ~ 1,500 r/min

----

Vacuum pressure at engine idling

35.0 ~ 41.0 kPa

----

speed

(263 ~ 308 mmHg, 10.4 ~ 12.1 inHg)

Compression pressure (at sea level)

net

----

Standard

2

----

1,400 kPa (14.0 kg/cm2, 199.1 psi) at

500 r/min

.

Minimum

1,100 kPa (11.0 kg/cm

----

, 156.5 psi)

Maximum

ScooterTime

----

1,650 kPa (16.5 kg/cm2, 234.7 psi)

Fuel

Recommended fuel

Unleaded gasoline only (USA)

----

Regular unleaded gasoline only (CDN)

----

Fuel tank capacity

.

Total

----

14.0 L (3.08 Imp gal, 3.70 US gal)

Engine oil

Lubrication system

Wet sump

----

Recommended oil

from

www

0

10

30

50

70

90

110 130 ˚F

Refer to the chart for the engine oil grade.

----

Downloaded

YAMALUBE 4 (20W40)

or SAE 20W40

YAMALUBE 4 (10W30)

or SAE 10W30

–20

–10

0

10

20

30

40

50 ˚C

Recommended engine oil grade

API service SE, SF, SG type or higher

----

Quantity

Total amount

1.70 L (1.50 Imp qt, 1.80 US qt)

----

Without oil filter element replace-

1.50 L (1.32 Imp qt, 1.59 US qt)

----

ment

With oil filter element replacement

1.70 L (1.50 Imp qt, 1.80 US qt)

----

Engine oil temperature

70 ~ 80 °C (158 ~ 176 °F)

----

Final transmission oil

Type

SAE10W-30 type SE motor oil

----

Quantity

0.25 L (0.22 Imp qt, 0.26 US qt)

----

2 - 2

				ENGINE SPECIFICATIONS				SPEC
	Item				Standard					Limit
Oil pump
Oil pump type				Trochoid					----
Inner-rotor-to-outer-rotor-tip clear-				0.07 mm					0.15 mm
ance				(0.0028 in)					(0.0059 in)
Outer-rotor-to-oil-pump-housing				0.013 ~ 0.036 mm					0.106 mm
clearance				(0.0005 ~ 0.0014 in)					(0.0042 in)
Oil-pump-housing-to-inner-and-outer				0.040 ~ 0.096 mm					0.166 mm
rotor clearance				(0.0016 ~ 0.0038 in)					(0.0065 in)
Cooling system
Radiator capacity				1.57 L (1.38 Imp qt, 1.66 US qt)					----
Radiator cap opening pressure				110.0 ~ 140.0 kPa					----
				(1.10 ~ 1.40 kg/cm2, 15.6 ~ 19.9 psi)
Radiator core						net
Width				260 mm (10.24 in)		.			----
Reduction ratio				37/22 × 25/37ScooterTime(1.136)					----
Height				148 mm (5.83 in)					----
Depth				24 mm (0.94 in)					----
Coolant reservoir
Capacity				0.32 L (0.28 Imp q , 0.34 US qt)					----
Water pump
Water pump type				Single-suction centrifugal pump					----
					.
Coolant temperature					www				----
				80 ~ 90 °C (176 ~ 194 °F)
Starting system type				Electric starter					----
Electric fuel injection			from
Type				1100-87C00-A					----
Maximum warpageDownloaded				----					0.05 mm
Manufacturer				AISAN					----
Spark plug
Model (manufacturer) × qu ntity				CR7E (NGK) × 1					----
Spark plug gap				0.7 ~ 0.8 mm (0.028 ~ 0.031 in)					----
Cylinder head
Volume				30.3 ~ 31.1 cm3 (1.85 ~ 1.90 cu.in)					----
									(0.002 in)

2 - 3

ENGINE SPECIFICATIONS SPEC

Item

Camshafts

Drive system

Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance

Intake camshaft lobe dimensions

A

B

Measurement A

Measurement B

Exhaust camshaft lobe dimensions

A

Measurement ADownloadedB Measurement B

Maximum camshaft runout

Standard	Limit
Chain drive (right)	----
24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in)	----
24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in)	----
0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)	0.08 mm
	(0.0031 in)

			net
		.
		ScooterTime		34.250 mm
34.350 ~ 34.450 mm (1.352 ~ 1.356 in)
				(1.3484 in)
24.950 ~ 25.050 mm (0.982 ~ 0.986 in)				24.850 mm
				(0.9783 in)
	.
from	www
33.450 ~ 33.550 mm (1.317 ~ 1.321 in)				33.350 mm
				(1.3130 in)
24.956 ~ 25.056 mm (0.983 ~ 0.986 in)				24.856 mm
				(0.9786 in)
----				0.03 mm
				(0.0012 in)

2 - 4

ENGINE SPECIFICATIONS

SPEC

Item

Standard

Limit

Timing chain

Model/number of links

DID SCR-0409 SV/136LE

----

Tensioning system

Automatic

----

Valves, valve seats, valve guides

Valve clearance (cold)

Intake

0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in)

----

Exhaust

0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in)

----

Valve dimensions

B

C

A

net

D

Head Diameter

Face Width

Seat Width

Margin Thickness

.

Valve seat width C

.ScooterTime

Valve head diameter A

Intake

30.9 ~ 31.1 mm (1.2165 ~ 1.2244 in)

----

Exhaust

27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in)

----

Valve face width B

Intake

1.838 ~ 2.687 mm (0.0724 ~ 0.1058 in)

----

Exhaust

1.697 ~ 2.828 mm (0.0668 ~ 0.1113 in)

----

Intake

www

1.6 mm

1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)

(0.06 in)

Exhaust

1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)

1.6 mm

Downloaded

from

(0.06 in)

Valve margin thickness D

Intake

0.85 ~ 1.15 mm (0.0335 ~ 0.0453 in)

----

Exhaust

0.85 ~ 1.15 mm (0.0335 ~ 0.0453 in)

----

Valve stem diameter

Intake

4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in)

4.945 mm

(0.1947 in)

Exhaust

4.960 ~ 4.975 mm (0.1953 ~ 0.1959 in)

4.930 mm

(0.1941 in)

Valve guide inside diameter

Intake

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.050 mm

(0.1988 in)

Exhaust

5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)

5.050 mm

(0.1988 in)

Valve-stem-to-valve-guide clearance

Intake

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.080 mm

(0.0031 in)

Exhaust

0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)

0.100 mm

(0.0039 in)

2 - 5

ENGINE SPECIFICATIONS

SPEC

Item

Standard

Limit

Valve stem runout

----

0.01 mm

(0.0004 in)

	Valve seat width
	Intake			1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)					1.6 mm
									(0.06 in)
	Exhaust			1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)					1.6 mm
									(0.06 in)
	Valve springs
	Free length						ScooterTime
	Intake								44.13 mm
				46.45 mm (1.83 in)				.net
									(1.74 in)
	Exhaust			46.45 mm (1.83 in)					44.13 mm
									(1.74 in)
	Installed length (valve closed)
	Intake			35.10 mm (1.38 in)					----
	Exhaust					.			----
				35.10 mm (1 38 in)
	Spring rate (K1)				www
	Intake			15.21		N/mm (1.55 kg/mm, 86.77 lb/in)			----
	Exhaust			from		N/mm (1.55 kg/mm, 86.77 lb/in)			----
				15.21
	Spring rate (K2)
	Intake	Downloaded		19.84		N/mm (2.02 kg/mm, 113.28 lb/in)			----
	Exhaust			19.84		N/mm (2.02 kg/mm, 113.28 lb/in)			----
	Compressed spring force (inst		lled)
	Intake			160.5		~ 184.7 N at 35.10 mm			----
				(16.37 ~ 18.83 kg at 35.10 mm,
				36.08		~ 41.52 lb at 1.38 in)
	Exhaust			160.5		~ 184.7 N at 35.10 mm			----
				(16.37 ~ 18.83 kg at 35.10 mm,
				36.08		~ 41.52 lb at 1.38 in)
	Spring tilt

Intake	----	2.0 mm
		(0.08 in)
Exhaust	----	2.0 mm
		(0.08 in)

2 - 6

ENGINE SPECIFICATIONS SPEC

Item	Standard
Winding direction (top view)
Intake	Clockwise
Exhaust	Clockwise

Cylinder
Cylinder arrangement									Forward-inclined single cylinder
Bore × stroke									83.0 × 73.0 mm (3.27 × 2.87 in)
Compression ratio									10.6 : 1
Bore									83.000 ~ 83.010 mm (3.2677 ~ 3.2681 in)
Maximum taper									----		.net
Piston
Piston-to-cylinder clearance											ScooterTime
									0.060 ~ 0.075 mm (0.0024 ~ 0.0030 in)
Diameter D									82.930 ~ 82.945 mm (3.2650 ~ 3.2656 in)
										.
							H			www
	D							from
Height H									5.0 mm (0.20 in)
Piston pin bore (in the piston)
Diameter	Downloaded								20.004 ~ 20.015 mm
									(0.7876 ~ 0.7880 in)
Offset									1.0 mm (0.0394 in)
Offset direction									Intake side
Piston pin
Outside diameter									19.991 ~ 20.000 mm
									(0.7870 ~ 0.7874 in)
Piston-pin-to-piston-pin-bore clear- 0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)
ance
Piston rings
Top ring
								B
Ring type		T							Barrel
Dimensions (B × T)									1.00 × 2.70 mm (0.04 × 0.11 in)
End gap (installed)									0.20 ~ 0.35 mm (0.0079 ~ 0.0138 in)
Ring side clearance									0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)

Limit

----

----

----

----

----

----

0.05 mm

(0.002 in)

0.15 mm

(0.0059 in)

----

----

20.045 mm

(0.7892 in)

----

----

19.971 mm

(0.7863 in)

0.074 mm

(0.0029 in)

----

----

0.50 mm

(0.0197 in)

0.100 mm

(0.0039 in)

2 - 7