OWNER'S MANUAL YP400T LIT-11626-18-38 5RU-28199-10 INTRODUCTION EAU10090 Congratulations on your purchase of the Yamaha YP400. This model is the result of Yamaha's vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this scooter. If you have any questions concerning the operation or maintenance of your scooter, please consult a Yamaha dealer. The design and manufacture of this Yamaha scooter fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the scooter. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual. IMPORTANT MANUAL INFORMATION EAU35820 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING CAUTION: NOTE: Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander, or a person inspecting or repairing the scooter. A CAUTION indicates special precautions that must be taken to avoid damage to the scooter. A NOTE provides key information to make procedures easier or clearer. NOTE: G This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold. G Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your scooter and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. EWA12580 WARNING PLEASE READ THIS MANUAL AND THE "YOU AND YOUR MOTORCYCLE: RIDING TIPS" BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER. DO NOT ATTEMPT TO OPERATE THIS SCOOTER UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS SCOOTER. IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE YP400T OWNER'S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-18-38 TABLE OF CONTENTS SAFETY INFORMATION ...................1-1 Further safe-riding points .................1-4 Location of important labels .............1-6 DESCRIPTION ...................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments..................2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................3-1 Main switch/steering lock .................3-1 Indicator and warning lights .............3-2 Speedometer ...................................3-2 Tachometer .....................................3-3 Multi-function display .......................3-3 Handlebar switches .........................3-6 Front brake lever .............................3-7 Rear brake lever ..............................3-8 Rear brake lock lever .......................3-8 Fuel tank cap ...................................3-9 Fuel ................................................3-10 Catalytic converter .........................3-11 Seats .............................................3-11 Adjusting the rider seat ..................3-12 Storage compartments ..................3-13 Sidestand .......................................3-14 Ignition circuit cut-off system .........3-15 PRE-OPERATION CHECKS...............4-1 Pre-operation check list ...................4-2 OPERATION AND IMPORTANT RIDING POINTS.................................. 5-1 Starting the engine .......................... 5-1 Starting off ....................................... 5-2 Acceleration and deceleration ......... 5-2 Braking ............................................ 5-2 Engine break-in ............................... 5-3 Parking ............................................ 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR .................................. 6-1 PERIODIC MAINTENANCE ............ 6-1 Owner's tool kit ................................ 6-2 Periodic maintenance chart for the emission control system .............. 6-3 General maintenance and lubrication chart ........................... 6-4 Removing and installing cowlings and panels ................................... 6-8 Checking the spark plug ................ 6-12 Canister ......................................... 6-14 Engine oil and oil filter element ..... 6-14 Final transmission oil ..................... 6-17 Coolant .......................................... 6-18 Air filter elements and check hoses and V-belt case air filter element ...................................... 6-20 Adjusting the throttle cable free play ............................................ 6-23 Adjusting the valve clearance ....... 6-23 Tires .............................................. 6-23 Cast wheels .................................. 6-25 Accessories and replacement parts ........................................... 6-26 Front and rear brake lever free play ............................................ 6-26 Adjusting the rear brake lock lever cable .......................................... 6-27 Checking the front and rear brake pads ........................................... 6-27 Checking the brake fluid level ....... 6-28 Changing the brake fluid ............... 6-29 Checking and lubricating the cables ........................................ 6-29 Checking and lubricating the throttle grip and cable ................ 6-30 Lubricating the front and rear brake levers ............................... 6-30 Checking and lubricating the centerstand and sidestand ........ 6-30 Checking the front fork .................. 6-31 Checking the steering ................... 6-32 Checking the wheel bearings ........ 6-32 Battery ........................................... 6-33 Replacing the fuses ...................... 6-34 Replacing a headlight bulb ........... 6-36 Tail/brake light ............................... 6-36 Replacing a front turn signal light bulb ............................................ 6-36 Replacing a rear turn signal light bulb ............................................ 6-37 TABLE OF CONTENTS Replacing the license plate light bulb ............................................6-38 Troubleshooting .............................6-39 Troubleshooting charts ..................6-40 SCOOTER CARE AND STORAGE ...........................................7-1 Care .................................................7-1 Storage ............................................7-3 SPECIFICATIONS ..............................8-1 CONSUMER INFORMATION..............9-1 Identification numbers .....................9-1 Scooter noise regulation ..................9-3 Maintenance record .........................9-4 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY .................................9-6 YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................9-8 SAFETY INFORMATION EAU10260 1 SCOOTERS ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS SCOOTER. HE OR SHE SHOULD: G OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF SCOOTER OPERATION. THE WARNINGS G OBSERVE AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL. G OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. G OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECES- SARY BY MECHANICAL CONDITIONS. Safe riding G Always make pre-operation checks. Careful checks may help prevent an accident. G This scooter is designed to carry the operator and passenger. G The failure of motorists to detect and recognize scooters in traffic is the predominating cause of automobile/scooter accidents. Many accidents have been caused by an automobile driver who did not see the scooter. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. G Therefore: Wear a brightly colored jacket. Use extra caution when approaching and passing through intersections, since intersections are the most likely places for scooter accidents to occur. Ride where other motorists can G G G G G see you. Avoid riding in another motorist's blind spot. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current driver's license. Make sure that you are qualified and that you only lend your scooter to other qualified operators. Know your skills and limits. Staying within your limits may help you to avoid an accident. We recommend that you practice riding your scooter where there is no traffic until you have become thoroughly familiar with the scooter and all of its controls. Many accidents have been caused by error of the scooter operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for G G G 1-1 SAFETY INFORMATION G G G G G G G G the speed). Always obey the speed limit and never travel faster than warranted by road and traffic conditions. Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. The operator should keep both hands on the handlebar and both feet on the footboard during operation to maintain control of the scooter. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. Never ride under the influence of alcohol or other drugs. This scooter is designed for on-road use only. It is not suitable for off-road use. Protective apparel The majority of fatalities from scooter accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. G Always wear an approved helmet. G Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. G The use of a jacket, substantial shoes, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. G Never wear loose-fitting clothes, otherwise they could catch on the control levers or wheels and cause injury or an accident. G Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protec1-2 tive clothing that covers your legs, ankles, and feet. G Passengers should also observe the above precautions. Modifications Modifications made to this scooter not approved by Yamaha, or the removal of original equipment, may render the scooter unsafe for use and may cause severe personal injury. Modifications may also make your scooter illegal to use. Loading and accessories Adding accessories or cargo to your scooter can adversely affect stability and handling if the weight distribution of the scooter is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your scooter. Use extra care when riding a scooter that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your scooter: 1 SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 196 kg (432 lb). When loading within this weight limit, keep the following in mind: G Cargo and accessory weight should be kept as low and close to the scooter as possible. Make sure to distribute the weight as evenly as possible on both sides of the scooter to minimize imbalance or instability. G Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the scooter before riding. Check accessory mounts and c ...