Yamaha XS400 (1976-1982) [13/34] Yamaha xs360 400

Содержание

• A sight glass in the crankcase is pro 1
• Below 15 c 59 f use sae 10w 30 service rating se or sf 1
• Checking oil level xs400gisg on 1
• General specifications ________________ 1
• In order to prevent possible confusion when ordering parts always refer to the engine and frame serial numbers 1
• Lubrication 1
• Maintenance 1
• Motor oil 1
• Note common maintenance procedures are explained in detail in general infor mation 1
• Recommended lubricants chart at the end of this section 1
• Serial number location 1
• Side of the steering lug while the engine number is located on a raised boss just be hind the right cylinder on the top of the crankcases 1
• Straight grades can also be used according 1
• The frame number is stamped on the right 1
• To ambient air temperatures as given in the 1
• Vided to enable the rider to check oil level at a glance when checking the motorcycle should be parked on the centerstand on a level surface 1
• When the air temperature is consistently 1
• When the average air temperature is above 5 c 41 f use yamalube 4 stroke oil or sae 20w 40 service rating se or sf 1
• Yamaha xs360 400 1
• Changing oil 2
• Filter screen 2
• Front forks 2
• Oil filter 2
• Other models 2
• Yamaha xs360 400 2
• Chassis lubrication 3
• Clutch 3
• Drive chain 3
• Service checks and adjustments 3
• Yamaha xs360 400 3
• Brakes front disc 4
• Rear disc 4
• Throttle cable 4
• Yamaha xs360 400 4
• Brake light switches 5
• Front drum 5
• Fuel system 5
• Headlight adjustment 5
• Petcock 5
• Rear drum 5
• Yamaha xs360 400 5
• Air filters 6
• Although major overhaul of the carbu 6
• Blow out the elements from the inside 6
• Carburetors 6
• Caution do not let gasoline spill on a hot engine 3 remove the four screws which secure 6
• Check the sealing washer and replace it 6
• Clean the filter screen in a solvent be 6
• Disconnect the fuel line from the petcock and the vacuum line from the manifold 6
• Each float bowl and carefully lower the bowls until they are clear of the float mechanism 6
• If it is damaged 6
• Install the petcock after the tank is 6
• Install them 6
• Intervals 6
• Maintenance data 6
• Make sure that the petcock is shut off 6
• Note after several such cleanings the elements should be replaced with new ones the service interval for replacement will depend upon the amount of dirt build up on the elements 5 refit the elements into their cases and 6
• Periodic maintenance 6
• Pilot jets these are fitted to the float bowl on 360 models and are on the carburetor bodies on 400 models blow the jets clear then rein stall clean any foreign matter out of the float bowls when installing position the bowls carefully to avoid damage to the floats tighten the screws gradually and evenly check for fuel leaks before operation 6
• Recommended lubricants 6
• Refitted check for leaks before operating the motorcycle 6
• Remove the case screws and separate 6
• Remove the gas tank drain off the fuel 3 unscrew the petcock securing nut or 6
• Remove the side covers 2 loosen the carburetor clamp remove 6
• Res position drain the fuel from the car buretor float bowls by removing the main jet cover bolt from the bottom of the float bowls 6
• Retors requires their removal as a unit the float bowls and jets can be cleaned with the units in place 6
• Set the petcock to the res position 6
• Sure to remove any foreign matter trapped in the screen as this will impede fuel flow if the screen cannot be cleaned or if it is punc tured or otherwise damaged it should be re placed 6
• The case halves removing the filter element 6
• The element case holder screw take off the securing band and remove the element case 6
• Two phillips screws depending upon the method of fastening and pull off the petcock 6
• Unscrew and remove the main and 6
• With compressed air 6
• Yamaha xs360 400 6
• Cam chain adjustment 7
• Compression test 7
• Contact breaker points 7
• Location 7
• Replacement 7
• Tune up 7
• Valve adjustment 7
• Yamaha xs360 400 7
• Dynamic timing 8
• Gapping 8
• Ignition timing breaker point models 8
• Lubrication 8
• Yamaha xs360 400 8
• Adjusting float level 9
• Carburetors 9
• Ignition timing xs400g sg h 9
• Static timing 9
• Synchronization 9
• Yamaha xs360 400 9
• Connect the vacuum gauges 5 start the engine and note the vacuum 10
• Ders must be within 5 cm hg 0 in hg adjust if necessary by turning the synchro nization screw in or out until the vacuum readings for the two cylinders is as identical as possible 10
• Feed line if necessary so that the synchro nization screw between the carburetors is ac cessible 10
• Idle speed and mixture 10
• Idle speed is set by means of the throt 10
• If the limiter caps are missing or if the 10
• Manifolds the vacuum gauge fitting for the right cylinder operates the fuel petcock dis connect the petcock line from the fitting and turn the petcock to the prime position for the duration of the procedure 10
• Note if the vacuum gauges read more than 5 cm hg 0 in hg at 1 200 rpm check the compression spark plugs igni tion timing and valve clearance 6 if vacuum gauges are not available a 10
• Pilot screws have been removed as during a carburetor overhaul pilot screw adjustment is accomplished by screwing the pilot screws in very carefully until lightly seated then backing them out 1 turns on 360 models and 1 turns on 400 models 10
• Readings at idle 1 200 rpm the two cylin 10
• Rough method of synchronizing the carbu retors may be carried out remove the car buretors as a unit from the motorcycle look into the engine side of the carburetors and note the relative positions of the edges of the butterflies in relation to the small by pass passages in the bottom of the bores both butterflies should be in the same position relative to these by pass holes 10
• Screw fitted to each carburetor the screws are fixed in position by means of idle limiter caps this is designed to reduce emissions therefore it is not generally necessary to ad just the pilot screws 10
• The idle mixture is controlled by a pilot 10
• The vacuum gauge fittings are on the 10
• Tle stop screw between the carburetors idle speed is 1 200 rpm and must be adjusted when the engine is at operating temperature 10
• Tune up specifications 10
• Yamaha xs360 400 10
• Cylinder head removal 11
• Engine and transmission 11
• Engine removal and installation 11
• Engine service 11
• Top end 11
• Yamaha xs360 400 11
• Cylinder and piston removal 12
• Cylinder head 12
• Inspection camshaft 12
• Rocker arms and shafts 12
• Valve assembly 12
• Yamaha xs360 400 12
• Cylinders and pistons 13
• Lapping 13
• Seat cutting 13
• Yamaha xs360 400 13
• Cylinder and piston installation 14
• Cylinder head installation 14
• Piston rings 14
• Yamaha xs360 400 14
• Clutch removal 15
• Crankcase cover components 15
• Yamaha xs360 400 15
• Gearshift mechanism removal 16
• Inspection 16
• Installation 16
• Kickstarter shaft removal 16
• Oil pump 16
• Yamaha xs360 400 16
• Alternator starter drive removal 17
• Case assembly 17
• Engine sprocket removal 17
• Inspection 17
• Installation 17
• Lower end and transmission 17
• Splitting the crankcases 17
• Transmission gear shift assembly removal 17
• Yamaha xs360 400 17
• Assembly 18
• Crankshaft removal 18
• Inspection 18
• Yamaha xs360 400 18
• 1 blue 19
• 2 black 19
• Before installing connecting rods on the 19
• Berance is towards the intake side of the engine be sure that the rods are installed so that the cap numbers align with the rod num bers 19
• Big end bearing no crankpin no 19
• Brown green 19
• Coat the con rod bolt threads with a 19
• Crankcase no journal no insert 19
• Crankpins thoroughly lubricate the bearings with motor oil install the rods so that the yamaha mark on both rods faces the left end of the crankshaft and the bearing protu 19
• Engine specifications 19
• Going to be replaced be sure that the weight codes stamped on the rod and cap match for both rods 19
• If one or both of the connecting rods is 19
• Insert 19
• Molybdenum disulphide lubricant and 19
• Replace big end bearing inserts with in 19
• Rod side play at the small end if the move ment exceeds 0 mm 0 19 in the big end bearing should be replaced 19
• Serts of the same color code if the color is no longer visible on the old insert select a re placement according to the following chart 19
• Torque them to 24 28 ft lbs 19
• With a dial gauge check connecting 19
• Yamaha xs360 400 19
• Checking oil pressure 20
• Engine specifications cont 20
• Engine torque specifications 20
• Inspection 20
• Installation 20
• Lubrication system 20
• Oil pump 20
• Operational description 20
• Removal 20
• Yamaha xs360 400 20
• Carburetors 21
• Fuel system 21
• Installation 21
• Lubrication system specifications 21
• Removal 21
• Yamaha xs360 400 21
• Disassembly 22
• Inspection 22
• Yamaha xs360 400 22
• Alternator output check 23
• Assembly 23
• Carburetor specifications 23
• Charging system 23
• Electrical system 23
• Field coiliarmature tests 23
• Fuel petcock 23
• Yamaha xs360 400 23
• Breaker point ignition 24
• Pick up coil removal and installation 24
• Rectifier 24
• Regulator 24
• Transistorized ignition 24
• Troubleshooting 24
• Yamaha xs360 400 24
• Brake light 25
• Electrical components 25
• Inspection 25
• Neutral indicator 25
• Starter motor service removal and installation 25
• Starter solenoid 25
• Starting system 25
• Taillight 25
• Testing 25
• Turn signals 25
• Yamaha xs360 400 25
• Oil pressure indicator 26
• Self cancelling turn signal system 26
• Wiring diagrams 26
• Yamaha xs360 400 26
• Yamaha xs360 400 27
• J xs400fonly 28
• Wiring diagrams 28
• Xs400 2e 28
• Xs400f 2f 28
• Yamaha xs360 400 28
• Chassis 29
• Wiring diagrams 29
• Yamaha xs360 400 29
• Bleeding 30
• Disc brake service 30
• Flushing 30
• Precautions 30
• Rear wheel assembly removal and installation 30
• Tubeless tires 30
• Wheel bearings 30
• Yamaha xs360 400 30
• Caliper 31
• Front disc brake pad replacement 31
• Master cylinder 31
• Yamaha xs360 400 31
• Disc service 32
• Dissassembly 32
• Front drum brake 32
• Front forks 32
• Inspection 32
• Rear disc brake 32
• Rear drum brake 32
• Removal 32
• Yamaha xs360 400 32
• Assembly 33
• Bearing adjustment 33
• Disassembly 33
• Inspection 33
• Installation 33
• Steering stem assembly 33
• Yamaha xs360 400 33
• Assembly 34
• Inspection 34
• Rear shocks 34
• Removal and installation 34
• Swing arm 34
• Yamaha xs360 400 34

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Yamaha XS360 400 the seat check the total amount of allowable movement in two directions using a dial gauge Maximum allowable clearances are 0 08 mm 0 003 in for the intake valves and 0 1 mm 0 004 in for the exhaust valves If the measured clearances exceed these amounts replace both valve and guide A quick check of the operational worth iness of a valave and guide can be ac complished by dipping the valve stem in oil and inserting it into its guide Place a finger over the other end of the guide Pull the valve a little way out of the guide and release it The valve should be drawn back into the guide by suction if the components are in ser viceable condition and a very small amount of grinding com pound to the valve seat in the head Spin the valve back and forth against the seat for sev eral seconds then remove the grinding com pound and inspect the pattern of the seat from which the dye will have been removed 2 The valve seat should be about 1 0 mm 0 04 in wide and even in width all around the valve The maximum acceptable seat width is 1 5 mm 0 06 in 3 If the seat is uniform in width but is too wide use a flat cutter then a 30 cutter to reduce the seat width to within specification 4 If the seat is centered on the valve face but is too narrow use a 45 cutter to increase the width to the proper specification 5 If the seat is too narrow and is towards the top edge of the face first use a flat cutter and then the 45 cutter 6 If the seat is too narrow and positioned towards the bottom edge of the face use a 30 cutter first then a 45 cutter LAPPING Oversized valve guides are Identified by a groove around the upper part of the guide 1 Valves should be lapped into their seats if the leakage test shows poor sealing if the seat has been recut if the valve edges or seat in the head are pitted if the motorcycle has covered considerable mileage or if new valves or guides are fitted 2 Clean off all carbon build up on the sur face of the combustion chamber Place three small dabs of valve lapping paste around the circumference of the valve head and place the valve into the guide 3 If you have a lapping tool use it as the manufacturer directs Usually the tool will turn the valve back and forth while rotating it Valve springs are Installed with the close colls around the seat at the same time Do not use arrows towards the head excessive pressure during the operation If you do not have such a tool a piece of 10 Measure the diameter of each valve thick fuel line placed over the valve stem stem at three places along the length of the works just as well Turn the valve back and Measure the piston diameter 11 mm 0 43 In valve Check the measurement against the forth and rotate it to a new position every few above the bottom edge of the skirt and perpen dicular to the wrist pin standard diameter given in the chart at the seconds NOTE Check the condition of the valve end of this section and replace the valve if face and seat frequently When a smooth any of the measurements is below the stan even finish is evident stop lapping Exces dard sive lapping may lead to a pocketed valve 11 To replace a valve guide heat the cyl 4 Remove the valve and clean it inder head in an oven to a temperature of 212 F 100 C Drive out the old guide s thoroughly Remove any traces of lapping with a suitable drift Drive in the new compound from the seat and the combustion chamber Swab out the guide with a cotton guide s until fully seated Use new o rings NOTE When replacing valve guides use swab soaked in a solvent Squirt a little oil the special oversized guides These are eas into the guide so that it may carry away any ily identified since they have a groove particles inside around the upper part of the guide CYLINDERS AND PISTONS too severe Sanding should be done in a After installation ream the new guide s 1 Make a visual inspection of the cylin cross hatch pattern If the damage is severe with a 7 mm reamer Clean the inside of der bore noting any imperfections The cyl more than about Mi in wide the pistons the guide thoroughly afterwards should be replaced inder walls should be uniformly smooth 12 After installing new guides the valve 4 The rings must be free to move in the 2 With an inside micrometer measure seat should be recut and the valve lapped in the diameter of each bore at the top middle piston grooves If they cannot either they 13 Check the width of the valve seat on and bottom Make measurements in two di are carbon clogged which necessitates the valve It should be about 1 0 mm 0 04 rections 90 apart both parallel and perpen replacing the rings and cleaning out the in all the way around If narrower or wider dicular to the piston wrist pins grooves or metal has been pushed into the than this or if width varies around the valve If the difference between the high and grooves by a piston seizure In this event the seat should be recut and the valve lapped lower measurement in any one direction pistons and rings must be replaced Carbonin taper is greater than 0 05 mm 0 002 in or clogged rings are almost always broken when NOTE Valve springs are progressively if the difference between two measurements an attempt is made to remove or free them wound When installing them be sure they at any point on the cylinder out of round so be prepared to buy a new set are fitted with the close coils towards the exceeds 0 01 mm 0 0004 in the cylinders 5 Pistons are available in four oversizes cylinder head should be bored to the next oversize and fit in increments of 0 25 mm ted with new pistons To determine piston diameter use a mi SEAT CUTTING 3 Make a visual inspection of the pis crometer and measure the diameter in a di 1 Use a machinist s dye to check the tons Scoring scuffing or seizure marks on rection perpendicular to the wrist pin at a width and position of the valve seat Apply the piston skirts may be removed with a fine point about 11 mm 0 43 in above the bot the dye to the valve s beveled seating area grade of emery or crocus cloth if they are not tom edge of the skirt 1275