Yamaha XS400 (1976-1982) [19/34] 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 Crankcase No Journal No Insert 3 4 5 1 2 Blue Black Brown Green 8 Coat the con rod bolt threads with a berance is towards the intake side of the disulphide lubricant and engine Be sure that the rods are installed so molybdenum that the cap numbers align with the rod num torque them to 24 28 ft lbs bers Engine Specifications XS360 CYLINDER Bore Max allowable taper Max allowable out of round 66 00 66 02 mm 2 5900 2 5908 in 0 05 mm 0 002 in 0 01 mm 0 0004 in PISTON Piston skirt to cylinder clearance Piston oversizes Wrist pin diameter PISTON RINGS Piston ring end gap installed Compression Oil Groove side clearance Top compression Lower compression Big end bearing insert number location Be sure that both rods have the same Identification numbers and that the numbers on rods and caps align 4 With a dial gauge check connecting rod side play at the small end If the move ment exceeds 0 5 mm 0 019 in the big end bearing should be replaced 5 Replace big end bearing inserts with in 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 Big End Bearing No Crankpin No 3 4 5 Blue Black Brown Green 6 If one or both of the connecting rods is going to be replaced be sure that the weight codes stamped on the rod and cap match for both rods 7 Before installing connecting rods on the 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 0 04 0 08 mm 0 0016 0 0032 in 0 03 0 07 mm 0 0012 0 0028 in 0 020 0 054 mm 0 00079 0 00213 in 38 70 mm 1 527 in 38 74 mm 1 525 in 32 08 mm 1 263 in 31 90 mm 1 256 in 0 03 mm 0 0012 in ROCKER ASSEMBLY Rocker arm bore diameter Rocker arm shaft diameter Shaft to bore clearance 13 000 13 018 mm 0 5120 0 5127 in 12 964 12 984 mm 0 51199859 0 51199937 in 0 016 0 054 mm 0 00063 0 00122 VALVES Valve seat width Intake valve stem diameter Exhaust valve stem diameter Valve to stem clearance Intake Exhaust Max allowable run out 1 0 1 1 mm 0 03937 0 04330 in 6 975 6 990 mm 0 2741 0 2746 in 6 955 6 970 mm 0 2732 0 2738 in 0 010 0 037 mm 0 00039 0 00145 in 0 030 0 057 mm 0 0012 0 0022 in 0 03 mm 0 0012 in 39 3 mm 1 547 in 42 8 mm 1 685 in 1 7 mm 0 067 in 2 5 1 9 mm 0 075 in 2 5 CRANKSHAFT Max allowable run out Crank bearing clearance Con rod big end clearance 0 02 mm 0 0008 in 0 020 0 044 mm 0 00079 0 00157 in 0 021 0 045 mm 0 00080 0 00180 in Engine Specifications XS400 CYLINDER Bore Max allowable taper Max allowable out of round PISTON Piston skirt to cylinder clearance Piston oversizes Insert 1 2 0 2 0 4 mm 0 008 0 016 in 0 2 0 9 mm 0 008 0 035 in CAMSHAFT Bearing clearance Intake lobe height service limit Exhaust lobe height service limit Intake lobe base circle service limit Exhaust lobe base circle service limit Max allowable run out VALVE SPRINGS Free length Inner Outer Tilt replacement limit Inner Outer When Installing the rods be sure that the YAMAHA mark faces the left side of the crank 0 030 0 050 mm 0 0012 0 0019 in 66 25 mm 2 608 in 66 50 mm 2 618 in 66 75 mm 2 628 in 67 00 mm 2 638 in 15 995 16 000 mm 0 6298 0 6300 in Wrist pin diameter PISTON RINGS Piston ring end gap installed Compression Oil Groove side clearance Top compression Lower compression CAMSHAFT Bearing clearance Intake lobe height service limit Exhaust lobe height service limit Intake lobe base circle service limit Exhaust lobe base circle service limit Max allowable run out 69 00 69 02 mm 2 7200 2 7208 in 0 05 mm 0 002 in 0 01 mm 0 0004 in 0 030 0 050 mm 0 0012 0 0019 in 69 25 mm 2 727 in 69 50 mm 2 736 in 69 75 mm 2 746 in 70 00 mm 2 756 in 15 995 16 000 mm 0 6298 0 6300 in 0 2 0 4 mm 0 008 0 016 in 0 2 0 9 mm 0 008 0 035 in 0 04 0 08 mm 0 0016 0 0032 in 0 03 0 07 mm 0 0012 0 0028 in 0 020 0 054 mm 0 00079 0 00213 in 39 38 mm 1 550 in 39 42 mm 1 552 in 32 12 mm 1 265 in 31 97 mm 1 259 in 0 03 mm 0 0012 in 1281