Yamaha XS360 (1976-1982) [9/34] 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 set so that proper mark alignment is achieved Tighten the screws 9 If it is not possible to achieve full ad vance alignment without moving the base plate or the right points set all the way to the end of their range of allowable travel it is possible that the points are either incorrectly gapped or that they are worn to the point where they must be replaced vertically lower the float until the float arm just touches but does not depress the tip of the float needle Float level is the measured distance from the bottom of the float to the float bowl mating surface Static Timing Full advance firing point Is Indicated by two lines 2 Remove the points cover and the al ternator rotor cover Clean and gap both sets of points as previously described 3 Hook up the strobe light according to the manufacturer s instructions to pick up impulses from the left cylinder 4 Start the engine and adjust the idle speed if necessary to 1 200 rpm 5 Aim the timing light at the marks on the alternator rotor visible through the cut out At idle the LF mark on the rotor should align with the stationary timing mark 6 To check the ignition timing at full ad vance increase engine speed until the motor is turning 2 500 3 000 rpm At this point the stationary timing mark should be between the two full advance marks scribed onto the alternator rotor 7 If adjustment is necessary loosen the two large base plate screws and rotate the 1 Remove the points cover and the alter nator rotor cover 2 Clean and gap both sets of points as de scribed previously 3 Connect one lead of the tester or test light to the primary wire terminal for the left cylinder orange lead and the other tester lead to ground on the engine or frame 4 If the test device is not self powered turn the ignition switch on and be sure the kill switch is in the middle position 5 Turn the engine over in the normal di rection of rotation until the LF mark aligns with the stationary timing mark The test in strument should react at the instant these marks align indicating that the points have opened If they do not loosen the two large screws which secure the points base plate and rotate the plate so that the points just open when the timing marks are in align ment Tighten the base plate screws and re check the timing 6 Repeat the procedure with the right points set If adjustment is necessary loosen the two screws which secure these points to their mounting plate and use a small screw driver at the pry point provided Tighten the screws and recheck the timing Checking float level 4 Float level for each model is given in the Tune Up Specifications chart at the end of this section Adjust if necessary by pushing out the float pivot pin removing the floats and bending the float arm tang Bend ing the tang towards the carburetor body will increase the float level measurement and vice versa 5 Both carburetors must have the same float level Measure both before changing ei ther Note that the measured float level will be inaccurate if the float needle tip is worn or if there is foreign matter on the needle seat IGNITION TIMING XS400G SG H Because of the transistorized spark unit which is used in place of the more conven tional breaker points ignition timing for these models need not be checked unless the pick up unit is removed If a check is required note that the LF timing mark on the rotor should align with the index mark at 1200 rpm Dynamic timing using a strobe light is the only method of checking the timing Adjustment is not pos sible If the marks are not properly aligned at the given speed the only cause would be a loose spark unit rotor bolt CARBURETORS Adjusting the float tang Carburetor adjustments to be made during a To adjust the timing for the left cylinder loosen the two breaker plate screws large arrows and tune up include setting float level synchro Synchronization rotate the entire plate To adjust the right cylin nization and idle speed and mixture der loosen the two point screws smaller arrows Vacuum gauges are necessary to properly and move the right cylinder s points synchronize the carburetors although a Adjusting Float Level rough approximation can be made by visually 1 Float level is a measure of the amount aligning the butterflies see below entire plate so that the proper marks align at the specified rpm Establishing this align of gasoline which will be in the float bowls The butterflies are synchronized by means ment at full advance is recommended during operation While it is a critical specifi of a single screw located between the two cation it will not normally need readjust carburetors Turning the screw simulta Tighten the base plate screws 8 Repeat the procedure this time hav ment once properly set Float level there neously closes one butterfly while opening ing the strobe light pick up the right cylin fore need not be checked at every tune up the other der If adjustment is necessary loosen the but should be attended to from time to time 1 Run the engine until operating temper 2 Remove the carburetors two small phillips screws which secure the ature is reached points set to its plate and use a small screw 3 Remove the float bowls Remove the 2 Remove the gas tank s rear mounting driver at the pry point provided to move the gasket With the carburetor s positioned bolt and raise the tank fitting a longer fuel 1271