YAMAHA YP400S PARTS CATALOGUE 04

YP400 (5RU1) EUROPE,SOUTH AFRICA
YP400S (5RU3) AUSTRALIA

1C5RU-300E1

2C5RU-300E1

()

YP400/YP400S

PARTS CATALOGUE

©2003 by Yamaha Motor Co., Ltd.

1st edition, December 2003

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan.

A3

A4

FOREWORD

This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are
ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers
and part names correctly.

1. Modifications or additions which have been made after the issue of the Parts Catalogue
will be announced in the Parts News.
It is advisable that you make the necessary corrections to the Parts Catalogue according
to the Parts News.

2. Abbreviations
The following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number.
“UN” Use as many as needed.
“AP” Alternate Parts
“LM” Locally Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
“O/S” Over Size

3. The number of components for assembly

• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the
part name as shown below.

• The numeral appearing to the right of each component part indicates the quantity of
parts for each assembly unit.

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

6. The asterisk (*) before a reference number indicates modified items after the first edition.

4. Applicable colours of graphics are represented in the “REMARKS” as shown below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4–24110–00–X5 FUEL TANK COMP. 2 MXR

3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR

5. Note that the illustrations for reference in finding parts numbers are not to be used for
assembling. When assembling, please use the applicable service manual.

A5

7. Applicable Serial No.

Engine Serial No. Frame Serial No.

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation Colour Name Colour Code

DBNM8(*) DARK BLUISH GRAY METALLIC 8 0919

DPBML(*) DARK PURPLISH BLUE METALLIC L 0865

S3(*) SILVER 3 0791

FOREWORD

A6

MODEL LABEL

(1) A label called “Model Label” is affixed in the location as indicated in (3) below.

When using this parts catalogue, please be sure to cross–reference the “model code –
production code No.” in the catalogue with the “model code – production code No.” indi­cated on the Model Label affixed onto the product concerned.

(2) “Model Label” Indication

(3) Model Label Affixing Location

(4) Colouring Information

Model Code

5RU1

5RU3

Colouring

Type Code

A 0791

B 0865

C 0919

A 0791

B 0865

C 0919

Colour

Code

Colour Name

SILVER 3 S3

DARK PURPLISH BLUE METALLIC L DPBML

DARK BLUISH GRAY METALLIC 8 DBNM8

SILVER 3 S3

DARK PURPLISH BLUE METALLIC L DPBML

DARK BLUISH GRAY METALLIC 8 DBNM8

Abbrevia-

tion

(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue

Model

Code

5RU1

5RU3 010 AUSTRALIA

Production

Code No.

010 ITALY

020 BELGIUM

030 SWITZERLAND

070

080 GREECE

090

100 NORWAY

110 PORTUGAL

120 SWEDEN

130 SOUTH AFRICA

Country

(destination)

UNITED KINGDOM

NETHERLANDS

Model

Code

Production

Code No.

Country

(destination)

A7

ENGINE

CYLINDER ............................................................................B2

CRANKSHAFT & PISTON ....................................................B4

VALVE ...................................................................................B5

CAMSHAFT & CHAIN ...........................................................B7

WATER PUMP ......................................................................B8

RADIATOR & HOSE .............................................................B9

OIL PUMP .............................................................................B11

INTAKE .................................................................................B13

INTAKE 2 ..............................................................................B15

EXHAUST .............................................................................C3

CRANKCASE ........................................................................C5

CRANKCASE COVER 1 .......................................................C7

STARTER ..............................................................................C9

CLUTCH ................................................................................C10

TRANSMISSION ...................................................................C11

CHASSIS

FRAME ..................................................................................C12

FENDER ................................................................................C15

SIDE COVER ........................................................................D2

REAR ARM & SUSPENSION ...............................................D4

STEERING ............................................................................D5

FUEL TANK ...........................................................................D7

SEAT .....................................................................................D8

FRONT WHEEL .................................................................... D11

FRONT BRAKE CALIPER ....................................................D12

REAR WHEEL .......................................................................D13

REAR BRAKE CALIPER .......................................................D14

STEERING HANDLE & CABLE ............................................D15

FRONT MASTER CYLINDER ...............................................E2

STAND & FOOTREST ..........................................................E4

LEG SHIELD .........................................................................E6

GENERATOR ........................................................................E8

STARTING MOTOR ..............................................................E9

FLASHER LIGHT ..................................................................E10

METER ..................................................................................E11

HEADLIGHT ..........................................................................E12

TAILLIGHT ............................................................................E13

HANDLE SWITCH & LEVER ................................................E14

ELECTRICAL 1 ..................................................................... E15

ELECTRICAL 2 .....................................................................F3

CONTENTS

INDEX

NUMERICAL INDEX ............................................................. M1

FIG. 1 CYLINDER

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5RU–11101–00

5JW–11133–10

93440–09141

90105–06026

90340–12112

95617–08620

94701–00353

5RU–11181–00

91318–06150

90201–06016

90179–10006

90176–10075

90201–103M4

99530–10014

5RU–11191–00

CYLINDER HEAD ASSY 1 1

.GUIDE, VALVE 1 4 4

.CIRCLIP 4 4

.BOLT, FLANGE 8 8

.PLUG, STRAIGHT SCREW 2 2

BOLT, STUD 2 2

PLUG, SPARK (NGK CR7E) 1 1

GASKET, CYLINDER HEAD 1 1 1

BOLT 2 2

WASHER, PLATE 2 2

NUT 2 2

NUT, CROWN 2 2

WASHER, PLATE 4 4

PIN, DOWEL 2 2

COVER, CYLINDER HEAD 1 1 1

5RU1

5RU3

REMARKS

B

2

16

5RU–11193–00

17

90464–09017

18

5RU–11138–00

19

5BE–12241–00

20

95027–06030

21

90109–066F0

22

4KG–1111G–00

23

95024–06012

24

90430–06014

25

5RU–11310–00

26

5RU–11351–00

27

93210–86509

GASKET, HEAD COVER 1 1 1

CLAMP 1 1

PLUG 2 2

GUIDE, STOPPER 2 1 1

BOLT, FLANGE 9 9

BOLT 1 1

RUBBER, MOUNT 1 1 1

BOLT, FLANGE 1 1

GASKET 1 1

CYLINDER 1 1

GASKET, CYLINDER 1 1

O-RING 1 1

FIG. 1 CYLINDER

REF.
NO.

28

PART NO. DESCRIPTION

95027–06030

BOLT, FLANGE 1 1

5RU1

5RU3

REMARKS

B

3

FIG. 2 CRANKSHAFT & PISTON

REF.
NO.

1

2

3

4

5

6

7

8

PART NO. DESCRIPTION

5RU–11400–00

90179–18004

90201–18016

90280–05001

93306–20116

93101–12002

99009–32500

5RU–11416–00

CRANKSHAFT ASSY 1 1

NUT 1 1

WASHER, PLATE 1 1

KEY, WOODRUFF 1 1

BEARING 1 1

OIL SEAL 1 1

CIRCLIP 1 1

PLANE BEARING, CRANKSHAFT 1 1 1 UR BLUE

5RU1

5RU3

REMARKS

5RU–11416–10

5RU–11416–20

5RU–11416–30

5RU–11416–A0

9

5RU–11417–00

5RU–11417–10

5RU–11417–20

5RU–11417–30

5RU–11417–A0

10

5RU–11500–00

11

5RU–13354–00

12

99009–17800

13

93306–30438

14

5RU–11631–00–A0

5RU–11636–09

15

5RU–11603–00

5RU–11605–09

PLANE BEARING, CRANKSHAFT 1 1 1 UR BLACK

PLANE BEARING, CRANKSHAFT 1 1 1 UR BROWN

PLANE BEARING, CRANKSHAFT 1 1 1 UR GREEN

PLANE BEARING, CRANKSHAFT 1 1 1 UR WHITE

PLANE BEARING, CRANKSHAFT 2 1 1 UR BLUE

PLANE BEARING, CRANKSHAFT 2 1 1 UR BLACK

PLANE BEARING, CRANKSHAFT 2 1 1 UR BROWN

PLANE BEARING, CRANKSHAFT 2 1 1 UR GREEN

PLANE BEARING, CRANKSHAFT 2 1 1 UR WHITE

BALANCER ASSY 1 1

SPROCKET, DRIVE 1 1

CIRCLIP 2 2

BEARING 2 2

PISTON (STD) 1 1

PISTON (0.50MM O/S) 1 1 AP

PISTON RING SET (STD) 1 1

PISTON RING SET (0.50MM O/S) 1 1 AP

B

4

16

5RU–11633–00

17

93450–22027

PIN, PISTON 1 1

CIRCLIP 2 2

FIG. 3 VALVE

REF.
NO.

1

2

3

4

5

6

7

8

PART NO. DESCRIPTION

5RU–12111–00

5RU–12121–00

5RU–12116–00

5RU–12113–00

33M–12119–00

5RU–12117–00

1AA–12118–00

5RU–12153–20

VALVE, INTAKE 2 2

VALVE, EXHAUST 2 2

SEAT, VALVE SPRING 4 4

SPRING, VALVE INNER 4 4

SEAL, VALVE STEM 4 4

RETAINER, VALVE SPRING 4 4

COTTER, VALVE 8 8

LIFTER, VALVE 4 4 UR BLUE

5RU1

5RU3

REMARKS

5RU–12153–30

5RU–12153–09

9

3LD–12168–00

3LD–12168–20

3LD–12168–40

3LD–12168–60

3LD–12168–80

3LD–12168–A0

3LD–12168–F0

3LD–12168–H1

3LD–12168–K1

3LD–12168–M1

3LD–12168–R1

3LD–12168–U1

3LD–12168–W1

3LD–12168–Y1

3LD–12169–11

LIFTER, VALVE 4 4 UR RED

LIFTER, VALVE 4 4 AP GREEN

PAD, ADJUSTING (1.20) 4 4 UR

PAD, ADJUSTING (1.25) 4 4 UR

PAD, ADJUSTING (1.30) 4 4 UR

PAD, ADJUSTING (1.35) 4 4 UR

PAD, ADJUSTING (1.40) 4 4 UR

PAD, ADJUSTING (1.45) 4 4 UR

PAD, ADJUSTING (1.50) 4 4 UR

PAD, ADJUSTING (1.55) 4 4 UR

PAD, ADJUSTING (1.60) 4 4 UR

PAD, ADJUSTING (1.65) 4 4 UR

PAD, ADJUSTING (1.70) 4 4 UR

PAD, ADJUSTING (1.75) 4 4 UR

PAD, ADJUSTING (1.80) 4 4 UR

PAD, ADJUSTING (1.85) 4 4 UR

PAD, ADJUSTING (1.90) 4 4 UR

B

5

3LD–12169–31

3LD–12169–50

PAD, ADJUSTING (1.95) 4 4 UR

PAD, ADJUSTING (2.00) 4 4 UR

FIG. 3 VALVE

REF.
NO.

9

PART NO. DESCRIPTION

3LD–12169–70

PAD, ADJUSTING (2.05) 4 4 UR

5RU1

5RU3

REMARKS

3LD–12169–90

3LD–12169–E0

3LD–12169–G0

3LD–12169–J0

3LD–12169–L0

3LD–12169–N0

3LD–12169–T0

PAD, ADJUSTING (2.10) 4 4 UR

PAD, ADJUSTING (2.15) 4 4 UR

PAD, ADJUSTING (2.20) 4 4 UR

PAD, ADJUSTING (2.25) 4 4 UR

PAD, ADJUSTING (2.30) 4 4 UR

PAD, ADJUSTING (2.35) 4 4 UR

PAD, ADJUSTING (2.40) 4 4 UR

B

6

FIG. 4 CAMSHAFT & CHAIN

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5RU–12171–00

5RU–12176–00

90105–07005

5RU–12181–00

5RU–12280–00

90105–07005

5TA–12288–00

5VK–12290–00

94581–89136

5RU–12231–00

5RU–12233–00

5RU–12241–00

5RU–12257–00

5RU–12243–00

90110–06226

CAMSHAFT 1 1 1

SPROCKET, CAM CHAIN 1 1

BOLT, FLANGE 2 2

CAMSHAFT 2 1 1

DECOMPRESSION ASSY 1 1

BOLT, FLANGE 2 2

CAM, DECOMPRESSION 1 1

LEVER, DECOMPRESSION SPRING 1 1

CHAIN 1 1

GUIDE, STOPPER 1 1 1

PLATE, GUIDE STOPPER 1 1 1

GUIDE, STOPPER 2 1 1

SHAFT 2 1 1

PLATE, GUIDE STOPPER 2 1 1

BOLT, HEXAGON SOCKET HEAD 3 3

5RU1

5RU3

REMARKS

B

7

16

5GJ–12210–10

17

4FM–12213–00

18

91317–06020

TENSIONER ASSY, CAM CHAIN 1 1

GASKET, TENSIONER CASE 1 1

BOLT 2 2

FIG. 5 WATER PUMP

REF.
NO.

1

2

3

4

5

6

7

8

9

PART NO. DESCRIPTION

5RU–12450–00

5RU–W1242–00

5RU–12439–00

91317–06025

93306–00013

90201–08382

99001–07600

93420–28055

93103–10011

IMPELLER SHAFT ASSY 1 1

COVER, HOUSING 1 1

O-RING 1 1

BOLT 3 3

BEARING 1 1

WASHER, PLATE 1 1

CIRCLIP 1 1

CIRCLIP 1 1

OIL SEAL 1 1

5RU1

5RU3

REMARKS

B

8

FIG. 6 RADIATOR & HOSE

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5RU–12446–01

93210–18417

90105–06049

5RU–12411–00

5RU–12413–00

5RU–13573–00

93210–064A5

93210–04122

95027–06035

5RU–14349–00

90467–09026

90464–11004

90464–08005

5RU–12461–00

5RU–12405–00

JOINT 1 1

O-RING 1 1

BOLT, FLANGE 1 1

THERMOSTAT 1 1

COVER, THERMOSTAT 1 1

BOLT 1 1 1

O-RING 1 1

O-RING 1 1

BOLT, FLANGE 2 2

PIPE, 1 1 1

CLIP 1 1

CLAMP 1 1

CLAMP 1 1

RADIATOR ASSY 1 1

BLOWER ASSY 1 1

5RU1

5RU3

REMARKS

B

9

16

5GJ–12675–00

17

4JH–12462–00

18

4HC–12591–00

19

97007–05012

20

5RU–12481–00

21

5RU–12482–00

22

5RU–12483–00

23

5RU–12484–00

24

5RU–12485–00

25

5RU–12476–00

26

90467–26131

27

90450–28014

BOLT, BLOWER HOLDING 4 4

CAP, RADIATOR 1 1

SUPT, FILLER NECK 1 1

BOLT 1 1

PIPE 1 1 1

PIPE 2 1 1

PIPE 3 1 1

PIPE 4 1 1

PIPE 5 1 1

PIPE 6 1 1

CLIP 1 1

HOSE CLAMP ASSY 3 3

FIG. 6 RADIATOR & HOSE

REF.
NO.

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

PART NO. DESCRIPTION

90467–22100

90501–14001

90450–28014

95807–06010

5RU–12466–00

93210–18003

90105–06049

5RU–12437–00

5RU–1246A–00

5RU–12414–00

95027–06035

5RU–12477–00

5RU–1248A–00

90450–32015

5RU–1243A–00

CLIP 2 2

SPRING, COMPRESSION 1 1

HOSE CLAMP ASSY 4 4

BOLT, FLANGE 3 3

EXCHANGER, HEAT 1 1

O-RING 2 2

BOLT, FLANGE 2 2

STOPPER 1 1

COVER 1 1 1

GASKET, COVER 1 1

BOLT, FLANGE 3 3

PIPE 7 1 1

PIPE 8 1 1

HOSE CLAMP ASSY 4 4

HOSE 1 1 1

5RU1

5RU3

REMARKS

B

10

43

90467–11090

CLIP 2 2

FIG. 7 OIL PUMP

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5RU–13300–00

5RU–13344–00

5RU–13325–00

93603–22028

90201–08512

99001–07600

5RU–13475–00

91317–06025

59V–11167–00

51Y–13411–00

90501–18576

5RU–15351–00

93210–35520

5RU–13381–00

5RU–13342–01

OIL PUMP ASSY 1 1

SHAFT, DRIVEN GEAR 1 1

GEAR, PUMP DRIVEN 1 1

PIN, DOWEL 1 1

WASHER, PLATE 3 3

CIRCLIP 2 2

GASKET 1 1

BOLT 2 2

PIPE, BREATHER 2 1 1

STRAINER, OIL 1 1

SPRING, COMPRESSION 1 1

PLUG, DRAIN 1 1 1

O-RING 1 1

DAMPER 1 1

SHAFT, IDLE GEAR 1 1

5RU1

5RU3

REMARKS

B

11

16

5RU–13355–00

17

99001–07600

18

90201–105E8

19

5RU–13341–00

20

93603–22028

21

90201–105E8

22

99001–09600

23

5RU–13490–00

24

93210–10096

25

5RU–13327–00

26

94580–25050

27

5RU–13440–00

SPROCKET, DRIVEN 1 1

CIRCLIP 2 2

WASHER, PLATE 1 1

GEAR, OIL PUMP IDLE 1 1

PIN, DOWEL 1 1

WASHER, PLATE 2 2

CIRCLIP 1 1

RELIEF VALVE ASSY 1 1

O-RING 1 1

COVER, GEAR 1 1

CHAIN 1 1

ELEMENT ASSY, OIL CLEANER 1 1

FIG. 7 OIL PUMP

REF.
NO.

28

29

30

31

32

PART NO. DESCRIPTION

90501–162E4

5RU–13447–00

95027–06020

93210–56589

93210–13016

SPRING, COMPRESSION 1 1

COVER, OIL ELEMENT 1 1

BOLT, FLANGE 3 3

O-RING 1 1

O-RING 1 1

5RU1

5RU3

REMARKS

B

12

FIG. 8 INTAKE

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5RU–13585–00

5PX–13569–00

90467–08075

5RU–13595–00

5RU–13556–00

90430–09005

95027–06035

5RU–13586–00

97027–06020

5RU–13930–00

90464–13073

90105–06059

92017–05012

5RU–13895–00

90467–07138

MANIFOLD 1 1

PLUG, BLIND 1 1

CLIP 2 2

JOINT 1 1

GASKET, MANIFOLD 1 1

GASKET 1 1

BOLT, FLANGE 2 2

JOINT, CARBURETOR 1 1 1

BOLT 2 2

PIPE INLET ASSEMBLY 1 1

CLAMP 1 1

BOLT, FLANGE 1 1

BOLT, BUTTON HEAD 1 1

HOSE, AIR 1 1

CLIP 1 1

5RU1

5RU3

REMARKS

B

13

16

5RU–14291–00

17

95027–06012

18

5RU–13750–00

19

5LB–14216–00

20

4KL–14415–00

21

5CA–14216–00

22

5LP–15484–00

23

5RU–14288–00

24

5RU–24411–00

25

5RU–14313–00

26

5LB–14216–00

27

5RU–85885–00

BRACKET 1 1 1

BOLT, FLANGE 3 3

THROTTLE BODY ASSY 1 1

.SCREW 2 2

.HOLDER, WIRE 2 2

.SCREW 2 2

.CLAMP 2 1 1

.SPRING 1 1

.DIAPHRAGM 1 1

.SUCTION PISTON 1 1

.SCREW 1 1

.THROTTLE SENSOR ASSY 1 1

FIG. 8 INTAKE

REF.
NO.

28

29

30

31

32

PART NO. DESCRIPTION

92017–05012

90450–57005

5RU–13892–00

90467–18196

90467–20030

.BOLT, BUTTON HEAD 1 1

HOSE CLAMP ASSY 1 1

HOSE, AIR 2 1 1

CLIP 1 1

CLIP 1 1

5RU1

5RU3

REMARKS

B

14

FIG. 9 INTAKE 2

REF.
NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5RU–14411–00

5RU–14412–00

5RU–1441A–00

5RU–14437–00

5RU–14451–00

5RU–14452–00

90480–13598

97707–50520

98907–05025

34X–1443E–00

90467–10008

5CA–14435–00

5CA–85886–00

5RU–14453–00

90387–064W3

CASE, AIR CLEANER 1 1 1

CAP, CLEANER CASE 1 1 1

COVER, CLEANER CASE 1 1 1

DUCT 1 1

ELEMENT, AIR CLEANER 1 1

SEAL 2 2

GROMMET 2 2

SCREW, TAPPING 3 3

SCREW, BIND 6 6

PIPE, DRAIN 1 1

CLIP 1 1

GROMMET 1 1

SENSOR, AIR TEMPRATURE 1 1

JOINT, AIR CLEANER 1 1 1

COLLAR 1 1

5RU1

5RU3

REMARKS

B

15

16

90109–067E6

17

90338–23004

18

5RU–14417–00

19

5RU–14421–00

20

5RU–14422–00

21

5RU–1441E–00

22

5RU–1443A–00

23

5RU–14461–00

24

5RU–14457–00

25

90480–13598

26

97707–50520

27

98907–05025

BOLT 1 1

PLUG 1 1

COVER 1 1 1

CASE, AIR CLEANER 2 1 1

CAP, CLEANER CASE 2 1 1

COVER, CLEANER CASE 2 1 1

DUCT 1 1

ELEMENT, AIR CLEANER 2 1 1

SEAL 2 2

GROMMET 2 2

SCREW, TAPPING 3 3

SCREW, BIND 5 5