Yamaha Xmax 400 Manual
Yamaha Xmax 400 Manual
Yamaha Xmax 400 Manual
OWNER’S MANUAL
YP400R
YP400RA
1SD-F8199-E1
EAU50921
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
DECLARATION of CONFORMITY
We
Company: YAMAHA MOTOR ELECTRONICS CO., LTD.
Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan
Revision record
No. Contents Date
1 To change contact person and integrate type-designation. 9 Jun. 2005
2 Version up the norm of EN60950 to EN60950-1 27 Feb. 2006
3 To change company name 1 Mar. 2007
version up of the following norm:
4 • EN300 330-2 v1.1.1 to EN300 330-2 v1.3.1 and EN300 330-2 v1.5.1 8 Jul. 2010
• EN60950-1:2001 to EN60950-1:2006/A11:2009
INTRODUCTION
EAU10114
WARNING
Please read this manual carefully and completely before operating this scooter.
A NOTICE indicates special precautions that must be taken to avoid damage to the
NOTICE vehicle or other property.
EAUM1012
YP400R/YP400RA
OWNER’S MANUAL
©2013 by MBK INDUSTRIE
1st edition, September 2013
All rights reserved
Any reprinting or unauthorized use
without the written permission of
MBK INDUSTRIE
is expressly prohibited.
Printed in France.
TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1 FOR YOUR SAFETY – Valve clearance............................. 6-20
Further safe-riding points ............... 1-5 PRE-OPERATION CHECKS .............4-1 Tires .............................................. 6-21
Cast wheels .................................. 6-22
DESCRIPTION .................................. 2-1 OPERATION AND IMPORTANT Checking the front and rear brake
Left view ......................................... 2-1 RIDING POINTS ................................5-1 lever free play ............................ 6-23
Right view....................................... 2-2 Starting the engine..........................5-1 Checking the front and rear brake
Controls and instruments ............... 2-3 Starting off ......................................5-2 pads .......................................... 6-24
Acceleration and deceleration ........5-3 Checking the brake fluid level ...... 6-24
INSTRUMENT AND CONTROL Braking............................................5-3 Changing the brake fluid .............. 6-26
FUNCTIONS...................................... 3-1 Tips for reducing fuel Checking and lubricating the
Immobilizer system......................... 3-1 consumption................................5-4 cables........................................ 6-26
Main switch/steering lock............... 3-2 Engine break-in ...............................5-4 Checking and lubricating the
Indicator lights and warning Parking ............................................5-5 throttle grip and cable ............... 6-26
lights............................................ 3-3 Lubricating the front and rear
Speedometer.................................. 3-5 PERIODIC MAINTENANCE AND brake levers............................... 6-27
Tachometer .................................... 3-6 ADJUSTMENT...................................6-1 Checking and lubricating the
Multi-function display ..................... 3-6 Owner’s tool kit ...............................6-2 centerstand and sidestand........ 6-27
Anti-theft alarm (optional) ............. 3-10 Periodic maintenance chart for the Checking the front fork................. 6-28
Handlebar switches...................... 3-10 emission control system..............6-3 Checking the steering................... 6-29
Front brake lever .......................... 3-11 General maintenance and Checking the wheel bearings ....... 6-29
Rear brake lever ........................... 3-12 lubrication chart...........................6-4 Battery .......................................... 6-29
ABS (for ABS models) .................. 3-12 Removing and installing panels ......6-8 Replacing the fuses ...................... 6-31
Fuel tank cap ................................ 3-13 Checking the spark plug ...............6-11 Replacing a headlight bulb ........... 6-32
Fuel............................................... 3-14 Engine oil and oil filter element .....6-13 Tail/brake light .............................. 6-33
Catalytic converters...................... 3-15 Final transmission oil.....................6-15 Front turn signal light.................... 6-33
Seat .............................................. 3-16 Coolant..........................................6-16 Replacing a rear turn signal light
Storage compartments................. 3-16 Air filter elements and check bulb ........................................... 6-33
Adjusting the shock absorber hoses and V-belt case air filter Replacing the license plate light
assemblies ................................ 3-18 element ......................................6-18 bulb ........................................... 6-34
Sidestand ..................................... 3-18 Checking the throttle grip free Auxiliary light ................................ 6-35
Ignition circuit cut-off system....... 3-19 play ............................................6-20 Troubleshooting............................ 6-35
TABLE OF CONTENTS
Troubleshooting charts .................6-36
SPECIFICATIONS..............................8-1
CONSUMER INFORMATION............9-1
Identification numbers.....................9-1
INDEX...............................................10-1
SAFETY INFORMATION
EAU1026B
Never operate a scooter without conspicuous appears to be very
1
proper training or instruction. Take effective in reducing the chance of
a training course. Beginners this type of accident.
Be a Responsible Owner should receive training from a cer- Therefore:
As the vehicle’s owner, you are re- tified instructor. Contact an autho- • Wear a brightly colored jacket.
sponsible for the safe and proper oper- rized scooter dealer to find out • Use extra caution when you are
ation of your scooter. about the training courses nearest approaching and passing
Scooters are single-track vehicles. you. through intersections, since in-
Their safe use and operation are de- tersections are the most likely
pendent upon the use of proper riding Safe Riding places for scooter accidents to
techniques as well as the expertise of Perform the pre-operation checks occur.
the operator. Every operator should each time you use the vehicle to make • Ride where other motorists can
know the following requirements be- sure it is in safe operating condition. see you. Avoid riding in another
fore riding this scooter. Failure to inspect or maintain the vehi- motorist’s blind spot.
He or she should: cle properly increases the possibility of • Never maintain a scooter with-
Obtain thorough instructions from an accident or equipment damage. out proper knowledge. Contact
a competent source on all aspects See page 4-1 for a list of pre-operation an authorized scooter dealer to
of scooter operation. checks. inform you on basic scooter
Observe the warnings and mainte- This scooter is designed to carry maintenance. Certain mainte-
nance requirements in this Own- the operator and a passenger. nance can only be carried out
er’s Manual. The failure of motorists to detect by certified staff.
Obtain qualified training in safe and recognize scooters in traffic is
and proper riding techniques. the predominating cause of auto-
Obtain professional technical ser- mobile/scooter accidents. Many
vice as indicated in this Owner’s accidents have been caused by
Manual and/or when made neces- an automobile driver who did not
sary by mechanical conditions. see the scooter. Making yourself
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SAFETY INFORMATION
Many accidents involve inexperi- • Always signal before turning or Protective Apparel
1
enced operators. In fact, many op- changing lanes. Make sure that The majority of fatalities from scooter
erators who have been involved in other motorists can see you. accidents are the result of head inju-
accidents do not even have a cur- The posture of the operator and ries. The use of a safety helmet is the
rent driver’s license. passenger is important for proper single most critical factor in the pre-
• Make sure that you are qualified control. vention or reduction of head injuries.
and that you only lend your • The operator should keep both Always wear an approved helmet.
scooter to other qualified opera- hands on the handlebar and Wear a face shield or goggles.
tors. both feet on the operator foot- Wind in your unprotected eyes
• Know your skills and limits. rests during operation to main- could contribute to an impairment
Staying within your limits may tain control of the scooter. of vision that could delay seeing a
help you to avoid an accident. • The passenger should always hazard.
• We recommend that you prac- hold onto the operator, the seat The use of a jacket, substantial
tice riding your scooter where strap or grab bar, if equipped, shoes, trousers, gloves, etc., is ef-
there is no traffic until you have with both hands and keep both fective in preventing or reducing
become thoroughly familiar with feet on the passenger footrests. abrasions or lacerations.
the scooter and all of its con- Never carry a passenger unless Never wear loose-fitting clothes,
trols. he or she can firmly place both otherwise they could catch on the
Many accidents have been feet on the passenger footrests. control levers or wheels and cause
caused by error of the scooter op- Never ride under the influence of injury or an accident.
erator. A typical error made by the alcohol or other drugs. Always wear protective clothing
operator is veering wide on a turn This scooter is designed for on- that covers your legs, ankles, and
due to excessive speed or under- road use only. It is not suitable for feet. The engine or exhaust sys-
cornering (insufficient lean angle off-road use. tem become very hot during or af-
for the speed). ter operation and can cause
• Always obey the speed limit and burns.
never travel faster than warrant- A passenger should also observe
ed by road and traffic condi- the above precautions.
tions.
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SAFETY INFORMATION
Avoid Carbon Monoxide Poisoning Do not run engine outdoors where When loading within this weight limit,
1
All engine exhaust contains carbon engine exhaust can be drawn into keep the following in mind:
monoxide, a deadly gas. Breathing a building through openings such Cargo and accessory weight
carbon monoxide can cause head- as windows and doors. should be kept as low and close to
aches, dizziness, drowsiness, nausea, the scooter as possible. Securely
confusion, and eventually death. Loading pack your heaviest items as close
Carbon Monoxide is a colorless, odor- Adding accessories or cargo to your to the center of the vehicle as pos-
less, tasteless gas which may be pres- scooter can adversely affect stability sible and make sure to distribute
ent even if you do not see or smell any and handling if the weight distribution the weight as evenly as possible
engine exhaust. Deadly levels of car- of the scooter is changed. To avoid the on both sides of the scooter to
bon monoxide can collect rapidly and possibility of an accident, use extreme minimize imbalance or instability.
you can quickly be overcome and un- caution when adding cargo or acces- Shifting weights can create a sud-
able to save yourself. Also, deadly lev- sories to your scooter. Use extra care den imbalance. Make sure that
els of carbon monoxide can linger for when riding a scooter that has added accessories and cargo are se-
hours or days in enclosed or poorly cargo or accessories. Here, along with curely attached to the scooter be-
ventilated areas. If you experience any the information about accessories be- fore riding. Check accessory
symptoms of carbon monoxide poi- low, are some general guidelines to fol- mounts and cargo restraints fre-
soning, leave the area immediately, get low if loading cargo to your scooter: quently.
fresh air, and SEEK MEDICAL TREAT- The total weight of the operator, pas- • Properly adjust the suspension
MENT. senger, accessories and cargo must for your load (suspension-ad-
Do not run engine indoors. Even if not exceed the maximum load limit. justable models only), and
you try to ventilate engine exhaust Operation of an overloaded vehicle check the condition and pres-
with fans or open windows and could cause an accident. sure of your tires.
doors, carbon monoxide can rap- • Never attach any large or heavy
idly reach dangerous levels. Maximum load: items to the handlebar, front
Do not run engine in poorly venti- YP400R 185 kg (408 lb) fork, or front fender. Such items
YP400RA 181 kg (399 lb)
lated or partially enclosed areas can create unstable handling or
such as barns, garages, or car- a slow steering response.
ports.
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SAFETY INFORMATION
This vehicle is not designed to nize that some aftermarket accesso- are added to the handlebar or
1
pull a trailer or to be attached to ries or modifications are not suitable front fork area, they must be as
a sidecar. because of potential safety hazards to lightweight as possible and
you or others. Installing aftermarket should be kept to a minimum.
Genuine Yamaha Accessories products or having other modifications • Bulky or large accessories may
Choosing accessories for your vehicle performed to your vehicle that change seriously affect the stability of
is an important decision. Genuine any of the vehicle’s design or operation the scooter due to aerodynamic
Yamaha accessories, which are avail- characteristics can put you and others effects. Wind may attempt to lift
able only from a Yamaha dealer, have at greater risk of serious injury or the scooter, or the scooter may
been designed, tested, and approved death. You are responsible for injuries become unstable in cross
by Yamaha for use on your vehicle. related to changes in the vehicle. winds. These accessories may
Many companies with no connection Keep the following guidelines in mind, also cause instability when
to Yamaha manufacture parts and ac- as well as those provided under “Load- passing or being passed by lar-
cessories or offer other modifications ing” when mounting accessories. ge vehicles.
for Yamaha vehicles. Yamaha is not in Never install accessories or carry • Certain accessories can dis-
a position to test the products that cargo that would impair the per- place the operator from his or
these aftermarket companies produce. formance of your scooter. Careful- her normal riding position. This
Therefore, Yamaha can neither en- ly inspect the accessory before improper position limits the
dorse nor recommend the use of ac- using it to make sure that it does freedom of movement of the
cessories not sold by Yamaha or not in any way reduce ground operator and may limit control
modifications not specifically recom- clearance or cornering clearance, ability, therefore, such accesso-
mended by Yamaha, even if sold and limit suspension travel, steering ries are not recommended.
installed by a Yamaha dealer. travel or control operation, or ob- Use caution when adding electri-
scure lights or reflectors. cal accessories. If electrical ac-
Aftermarket Parts, Accessories, and • Accessories fitted to the han- cessories exceed the capacity of
Modifications dlebar or the front fork area can the scooter’s electrical system, an
While you may find aftermarket prod- create instability due to improp- electric failure could result, which
ucts similar in design and quality to er weight distribution or aerody- could cause a dangerous loss of
genuine Yamaha accessories, recog- namic changes. If accessories lights or engine power.
1-4
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SAFETY INFORMATION
Aftermarket Tires and Rims cation for the straps carefully so EAU57600
1
The tires and rims that came with your the straps will not rub against Further safe-riding points
scooter were designed to match the painted surfaces during transport. Be sure to signal clearly when
performance capabilities and to pro- The suspension should be com- making turns.
vide the best combination of handling, pressed somewhat by the tie- Braking can be extremely difficult
braking, and comfort. Other tires, rims, downs, if possible, so that the on a wet road. Avoid hard braking,
sizes, and combinations may not be scooter will not bounce exces- because the scooter could slide.
appropriate. Refer to page 6-21 for tire sively during transport. Apply the brakes slowly when
specifications and more information on stopping on a wet surface.
replacing your tires. Slow down as you approach a
corner or turn. Once you have
Transporting the Scooter completed a turn, accelerate
Be sure to observe following instruc- slowly.
tions before transporting the scooter in Be careful when passing parked
another vehicle. cars. A driver might not see you
Remove all loose items from the and open a door in your path.
scooter. Railroad crossings, streetcar rails,
Point the front wheel straight iron plates on road construction
ahead on the trailer or in the truck sites, and manhole covers be-
bed, and choke it in a rail to pre- come extremely slippery when
vent movement. wet. Slow down and cross them
Secure the scooter with tie-downs with caution. Keep the scooter up-
or suitable straps that are at- right, otherwise it could slide out
tached to solid parts of the scoot- from under you.
er, such as the frame or upper The brake pads or linings could
front fork triple clamp (and not, for get wet when you wash the scoot-
example, to rubber-mounted han- er. After washing the scooter,
dlebars or turn signals, or parts check the brakes before riding.
that could break). Choose the lo-
1-5
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SAFETY INFORMATION
Always wear a helmet, gloves,
1
trousers (tapered around the cuff
and ankle so they do not flap), and
a brightly colored jacket.
Do not carry too much luggage on
the scooter. An overloaded scoot-
er is unstable. Use a strong cord
to secure any luggage to the carri-
er (if equipped). A loose load will
affect the stability of the scooter
and could divert your attention
from the road. (See page 1-3.)
1-6
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DESCRIPTION
EAU10411
Left view
2 1 2 3 4 5 6 7
12 11 10 9 8
1. Headlight (page 6-32) 9. Air filter element (left) (page 6-18)
2. Battery (page 6-29) 10.Engine oil filter element (page 6-13)
3. Main fuse (page 6-31) 11.Sidestand (page 3-18)
4. Coolant reservoir cap (page 6-16) 12.Front brake pads (page 6-24)
5. Coolant level check window (page 6-16)
6. Rear storage compartment (page 3-16)
7. V-belt case air filter element (page 6-18)
8. Shock absorber assembly spring preload adjusting ring (page 3-18)
2-1
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DESCRIPTION
EAU10421
Right view
1 2 3 4
2
7 6 5
1. Grab bar (page 5-2)
2. Seat (page 3-16)
3. Fuel tank cap (page 3-13)
4. Fuses (page 6-31)
5. Centerstand (page 6-27)
6. Air filter element (right) (page 6-18)
7. Shock absorber assembly spring preload adjusting ring (page 3-18)
2-2
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DESCRIPTION
EAU10431
12 11 10 9 8
1. Rear brake lever (page 3-12) 9. Front storage compartment B (page 3-16)
2. Left handlebar switches (page 3-10) 10.Main switch/steering lock (page 3-2)
3. Speedometer (page 3-5) 11.Coolant level check window (page 6-16)
4. Multi-function display (page 3-6) 12.Front storage compartment A (page 3-16)
5. Tachometer (page 3-6)
6. Right handlebar switches (page 3-10)
7. Front brake lever (page 3-11)
8. Throttle grip (page 6-20)
2-3
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3-1
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3-2
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the left. OI
L
CH
AN
3-3
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3-4
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OI
L
CH
AN
GE
ZAUM1005
1. Speedometer
UK ONLY
6070
50 80
40
100 12 90
30 60 0MPH 0
8
14
100
01
20
20 40
60 180
1 10 km/h
110
0 120
OI
L
CH
AN
GE
ZAUM1006
1. Speedometer
3-5
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1 WARNING
Be sure to stop the vehicle before
OUT TEMP
making any setting changes to the
3 multi-function display. Changing
1/2
°C
V-belt
2 settings while riding can distract the
TRIP 2
operator and increase the risk of an
accident. ZAUM1009
CLOCK
2. Oil change indicator “OIL CHANGE”
1. Tachometer 3. Icy road warning indicator “ ”
1
2. Tachometer red zone
2 OUT TEMP
The multi-function display is equipped
The electric tachometer allows the rid- 1/2 with the following:
°C
er to monitor the engine speed and 3 7 a fuel meter
keep it within the ideal power range. a coolant temperature meter
4 ODO
ZAUM1056
3-9
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reading may be affected when rid- Anti-theft alarm (optional) Handlebar switches
ing slowly (approximately under This model can be equipped with an
Left
20 km/h (12.5 mi/h)) or when optional anti-theft alarm by a Yamaha
stopped at traffic signals, railroad dealer. Contact a Yamaha dealer for
crossings, etc. more information.
3
1. Pass switch “ ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
Right
1. Hazard switch “ ”
2. Start switch “ ”
3-10
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3-11
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3-12
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1
1
2
ZAUM1014
3-13
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WARNING
EAUM3110
3 Gasoline and gasoline vapors are
extremely flammable. To avoid fires
2 Recommended fuel:
and explosions and to reduce the
risk of injury when refueling, follow ZAUM1015 Premium unleaded gasoline (Gaso-
1. Fuel tank filler tube hol (E10) acceptable)
these instructions. Fuel tank capacity:
2. Maximum fuel level
1. Before refueling, turn off the en- 14.0 L (3.70 US gal, 3.08 Imp.gal)
3. Wipe up any spilled fuel immedi- Fuel reserve amount (when the fuel
gine and be sure that no one is sit-
ting on the vehicle. Never refuel ately. NOTICE: Immediately level warning indicator flashes):
2.0 L (0.53 US gal, 0.44 Imp.gal)
while smoking, or while in the vi- wipe off spilled fuel with a clean,
cinity of sparks, open flames, or dry, soft cloth, since fuel may ECA11401
3-15
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1. Open.
it down to lock it in place.
2. Storage compartment opening lever
2. Remove the key from the main
3. Lid
switch if the scooter will be left un-
attended. To open the storage compartment
when it is locked, insert the key into the
1. Open. TIP
lock, turn it clockwise, and then pull on
Make sure that the seat is properly se-
the lever.
TIP cured before riding.
To open the storage compartment
Do not push inward when turning the when it is unlocked, simply pull on the
key. lever.
3. Fold the seat up. To lock the storage compartment,
push the lid into the original position,
insert the key into the lock, turn it coun-
terclockwise, and then remove it.
3-16
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3-17
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Adjusting the shock absorber adjusting ring with the position in- Sidestand
assemblies dicator on the shock absorber.
Use the spring preload adjusting
EWA10211
1
WARNING tool included in the owner’s tool
Always adjust both shock absorber kit to make this adjustment.
3
assemblies equally, otherwise poor
handling and loss of stability may re-
3
4
3
sult. 1
2
1. Sidestand switch
ing ring. 2
ECA10102
The sidestand is located on the left
NOTICE side of the frame. Raise the sidestand
To avoid damaging the mechanism, ZAUM1019 or lower it with your foot while holding
do not attempt to turn beyond the 1. Position indicator the vehicle upright.
maximum or minimum settings. 2. Spring preload adjusting ring
3. Spring preload adjusting tool TIP
Adjust the spring preload as follows. The built-in sidestand switch is part of
To increase the spring preload and Spring preload setting: the ignition circuit cut-off system,
thereby harden the suspension, turn Minimum (soft): which cuts the ignition in certain situa-
the adjusting ring on each shock ab- 1 tions. (See the following section for an
sorber assembly in direction (a). To de- Standard:
2 explanation of the ignition circuit cut-
crease the spring preload and thereby Maximum (hard): off system.)
soften the suspension, turn the adjust- 4
ing ring on each shock absorber as-
sembly in direction (b).
3-18
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3-19
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NO YES
3-20
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Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
EWA11152
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer. 4
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
4-1
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• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake • Replace if necessary. 6-23, 6-24, 6-24
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
4 • Check throttle grip free play.
Throttle grip 6-20, 6-26
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing.
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires 6-21, 6-22
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
Brake levers 6-27
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
Centerstand, sidestand 6-27
• Lubricate pivots if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
—
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-18
• If system is not working correctly, have Yamaha dealer check vehicle.
4-2
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5-1
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1. Grab bar
WARNING
Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the scooter
(b) may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road con-
(a) struction sites, and manhole 5
covers become extremely slip- Rear
The speed can be adjusted by opening pery when wet. Therefore, slow
and closing the throttle. To increase down when approaching such
the speed, turn the throttle grip in di- areas and cross them with cau-
rection (a). To reduce the speed, turn tion.
the throttle grip in direction (b). Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as brak-
ing downhill can be very diffi-
cult.
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually in-
creasing the pressure.
5-3
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your riding style. Consider the follow- between 0 and 1600 km (1000 mi). For NOTICE
ing tips to reduce fuel consumption: this reason, you should read the fol- Keep the engine speed out of
Avoid high engine speeds during lowing material carefully. the tachometer red zone.
acceleration. Since the engine is brand new, do not If any engine trouble should oc-
Avoid high engine speeds with no put an excessive load on it for the first cur during the engine break-in
load on the engine. 1600 km (1000 mi). The various parts in period, immediately have a
5 Turn the engine off instead of let- the engine wear and polish themselves Yamaha dealer check the vehi-
ting it idle for an extended length to the correct operating clearances. cle.
of time (e.g., in traffic jams, at traf- During this period, prolonged full-throt-
fic lights or at railroad crossings). tle operation or any condition that
might result in engine overheating
must be avoided.
EAU34322
5-4
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Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10312
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to 5
touch them and be burned.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
5-5
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WARNING WARNING
Periodic inspection, adjustment, and Turn off the engine when performing Brake discs, calipers, drums, and
lubrication will keep your vehicle in the maintenance unless otherwise linings can become very hot during
safest and most efficient condition specified. use. To avoid possible burns, let
possible. Safety is an obligation of the A running engine has moving brake components cool before
vehicle owner/operator. The most im- parts that can catch on body touching them.
portant points of vehicle inspection, parts or clothing and electrical
adjustment, and lubrication are ex- parts that can cause shocks or
plained on the following pages. fires.
The intervals given in the periodic Running the engine while ser-
maintenance charts should be simply vicing can lead to eye injury,
considered as a general guide under burns, fire, or carbon monoxide
6 normal riding conditions. However, de- poisoning – possibly leading to
pending on the weather, terrain, geo- death. See page 1-3 for more in-
graphical location, and individual use, formation about carbon monox-
the maintenance intervals may need to ide.
be shortened.
EWA10322 EWA10331
WARNING WARNING
Failure to properly maintain the vehi- This scooter is designed for use on
cle or performing maintenance ac- paved roads only. If this scooter is
tivities incorrectly may increase operated in abnormally dusty, mud-
your risk of injury or death during dy or wet conditions, the air filter el-
service or while using the vehicle. If ement should be cleaned or
you are not familiar with vehicle ser- replaced more frequently, otherwise
vice, have a Yamaha dealer perform rapid engine wear may result. Con-
service. sult a Yamaha dealer for proper
maintenance intervals.
6-1
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6-2
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TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46911
6-3
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6-4
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6-5
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EAU34492
TIP
Engine air filters and V-belt air filter
• This model’s engine air filters are equipped with disposable oil-coated paper elements, which must not be cleaned
with compressed air to avoid damaging them.
• The engine air filter elements need to be replaced and the V-belt air filter element needs to be serviced more fre-
quently when riding in unusually wet or dusty areas.
6-6
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6-7
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ZAUM1022
1
1. Panel B
2. Panel C
6
1
1
ZAUM1024
2
1. Panel A
1. Panel A
2. Screw
ZAUM1021
To install the panel
1. Panel D Place the panel in the original position,
and then install the screws.
6-8
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1 1
2 2
1 ZAUM1046 ZAUM1047
6-9
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6-10
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1. Storage compartment
2. Bolt
6-11
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TIP NOTICE
Make sure that the O-rings are properly Do not use oils with a diesel
seated. specification of “CD” or oils of a
higher quality than specified. In
8. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
6-14
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“ENERGY CONSERVING II” or ton, and the oil change indicator Final transmission oil
higher. will go off. The final transmission case must be
Be sure no foreign material en- checked for oil leakage before each
TIP ride. If any leakage is found, have a
ters the crankcase.
If the engine oil is changed before the Yamaha dealer check and repair the
10. Start the engine, and then let it idle oil change indicator comes on (i.e. be- scooter. In addition, the final transmis-
for several minutes while checking fore the periodic oil change interval has sion oil must be changed as follows at
it for oil leakage. If oil is leaking, been reached), the indicator must be the intervals specified in the periodic
immediately turn the engine off reset after the oil change for the next maintenance and lubrication chart.
and check for the cause. periodic oil change to be indicated at 1. Start the engine, warm up the final
11. Reset the oil change indicator ac- the correct time. To reset the oil chan- transmission oil by riding the
cording to the following proce- ge indicator before the periodic oil scooter for several minutes, and
6 dure. change interval has been reached, fol- then stop the engine.
low the above procedure, but note that 2. Place the scooter on the center-
To reset the oil change indicator the indicator will come on for 1.4 sec- stand.
1. Turn the key to “ON”. onds after releasing the “OIL CHAN- 3. Place an oil pan under the final
2. Hold the “OIL CHANGE” button GE” button, otherwise repeat the transmission case to collect the
pushed for 15 to 20 seconds. procedure. used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the fi-
nal transmission case.
OI
L
CH
AN
GE
1
ZAUM1051
6-15
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1. Screw
6. Install the rubber caps. 1. Air filter check hose 2. V-belt air filter case cover
2. If dirt or water is visible, remove 4. Remove the V-belt case air filter
6 To clean the air filter check hoses
the hose, clean it, and then install element by removing the screws.
1. Check the hose at the bottom of
it.
both air filter cases for accumulat-
ed dirt or water. 1
Cleaning the V-belt case air filter el-
Left ement
1. Remove panel A. (See page 6-8.)
2. Remove the left air filter case cov- 1
er.
3. Remove the V-belt air filter case
cover by removing the screws. 2
1. Screw
2. V-belt case air filter element
1
1. Air filter check hose
6-19
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element to remove most of the Checking the throttle grip free Valve clearance
dust and dirt, and then blow out play The valve clearance changes with use,
the dirt with compressed air as resulting in improper air-fuel mixture
shown. and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
6-20
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6-22
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WARNING
1 A soft or spongy feeling in the brake
lever can indicate the presence of
2 air in the hydraulic system. If there is
1. Valve stem nut air in the hydraulic system, have a
2. Valve stem locknut Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
6 Tightening torques: ZAUM1049
hydraulic system will diminish the
Valve stem nut: 1. No brake lever free play braking performance, which may re-
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) sult in loss of control and an acci-
Valve stem locknut: Rear dent.
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
ZAUM1050
6-23
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Checking the front and rear peared, have a Yamaha dealer replace Checking the brake fluid level
brake pads the brake pads as a set. Before riding, check that the brake fluid
The front and rear brake pads must be is above the minimum level mark.
checked for wear at the intervals spec- EAU34211 Check the brake fluid level with the top
ified in the periodic maintenance and Rear brake pads of the reservoir level. Replenish the
lubrication chart. Have a Yamaha dealer check each rear brake fluid if necessary.
brake pad for damage and measure
EAU22431 the lining thickness and if necessary, Front brake
Front brake pads replace them as a set.
1
6
ZAUM1057
6-24
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Changing the brake fluid Checking and lubricating the Checking and lubricating the
Have a Yamaha dealer change the cables throttle grip and cable
brake fluid at the intervals specified in The operation of all control cables and The operation of the throttle grip
the periodic maintenance and lubrica- the condition of the cables should be should be checked before each ride. In
tion chart. In addition, have the oil seals checked before each ride, and the ca- addition, the cable should be lubricat-
of the master cylinders and calipers as bles and cable ends should be lubri- ed by a Yamaha dealer at the intervals
well as the brake hoses replaced at the cated if necessary. If a cable is specified in the periodic maintenance
intervals listed below or whenever they damaged or does not move smoothly, chart.
are damaged or leaking. have a Yamaha dealer check or re- The throttle cable is equipped with a
Oil seals: Replace every two place it. WARNING! Damage to the rubber cover. Make sure that the cover
years. outer housing of cables may result is securely installed. Even though the
Brake hoses: Replace every four in internal rusting and cause inter- cover is installed correctly, it does not
years. 6
ference with cable movement. Re- completely protect the cable from wa-
place damaged cables as soon as ter entry. Therefore, use care not to
possible to prevent unsafe condi- pour water directly onto the cover or
tions. [EWA10712] cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
Recommended lubricant: clean with a moist cloth.
Yamaha cable lubricant or other
suitable cable lubricant
6-26
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Lubricating the front and rear Recommended lubricant: Checking and lubricating the
Silicone grease
brake levers centerstand and sidestand
Front brake lever
6 1. Sidestand
ZAUM1033
1. Centerstand
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
6-27
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6-28
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WARNING
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
6-29
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10
10
20
7.5
10
possibly a fire. [EWA15132]
TIP TIP 7.5 10
20
The main fuse, which is in a different Fuse tongs are included in the owner’s
and hard-to-reach location, must be tool kit. Use the tongs to remove and 7
replaced by a Yamaha dealer. install a fuse. 10
ZAUM1037
1. Main fuse
1. Fuse box
2. Spare main fuse
6-31
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10
10
20
7.5
10
6-32
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Tail/brake light Front turn signal light Replacing a rear turn signal
This model is equipped with an LED- If a front turn signal light does not light bulb
type tail/brake light. come on, have a Yamaha dealer check 1. Place the scooter on the center-
If the tail/brake light does not come on, its electrical circuit or replace the bulb. stand.
have a Yamaha dealer check it. 2. Open the seat. (See page 3-16.)
3. Remove the rear storage com-
partment by removing the bolts.
4. Remove the socket (together with
the turn signal light bulb) by turn-
ing it counterclockwise.
1
6
2
ZAUM1052
1. Bolt
2. Storage compartment
6-33
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ZAUM1038
ZAUM1039
6-34
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WARNING
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
6-35
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Troubleshooting charts
1. Fuel
There is enough fuel. Check the battery.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the battery.
6-36
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WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the
detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap
while turning it counterclockwise, and then remove the cap.
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
TIP
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended cool-
ant as soon as possible.
6-37
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sure to consult a Yamaha dealer for high-quality components are used. A NOTICE
advice on what products to use be- rusty exhaust pipe may go unnoticed Avoid using strong acidic wheel
fore cleaning the vehicle. Using a on a car, however, it detracts from the cleaners, especially on spoked
brush, harsh chemical products or overall appearance of a scooter. Fre- wheels. If such products are
cleaning compounds when cleaning quent and proper care does not only used on hard-to-remove dirt, do
these parts will scratch or damage comply with the terms of the warranty, not leave the cleaner on the af-
their surface. Wax also should not but it will also keep your scooter look- fected area any longer than in-
be applied to any matte colored fin- ing good, extend its life and optimize structed. Also, thoroughly rinse
ished parts. its performance. the area off with water, immedi-
ately dry it, and then apply a cor- 7
Before cleaning rosion protection spray.
1. Cover the muffler outlet with a Improper cleaning can damage
plastic bag after the engine has plastic parts (such as cowlings,
cooled down. panels, windshields, headlight
2. Make sure that all caps and cov- lenses, meter lenses, etc.) and
ers as well as all electrical cou- the mufflers. Use only a soft,
plers and connectors, including clean cloth or sponge with wa-
the spark plug cap, are tightly in- ter to clean plastic. However, if
stalled. the plastic parts cannot be thor-
3. Remove extremely stubborn dirt, oughly cleaned with water, di-
like oil burnt onto the crankcase, luted mild detergent with water
with a degreasing agent and a may be used. Be sure to rinse
brush, but never apply such prod-
7-1
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WARNING TIP
visibility and which cannot be easily
Consult a Yamaha dealer for ad-
recognized. Contaminants on the brakes or tires
vice on what products to use.
can cause loss of control.
Washing, rainy weather or humid
After cleaning Make sure that there is no oil or
climates can cause the headlight
1. Dry the scooter with a chamois or wax on the brakes or tires. If
lens to fog. Turning the headlight
an absorbing cloth. necessary, clean the brake
on for a short period of time will
2. Use a chrome polish to shine discs and brake linings with a
help remove the moisture from the
chrome, aluminum and stainless- regular brake disc cleaner or
lens.
steel parts, including the exhaust acetone, and wash the tires with
system. (Even the thermally in- warm water and a mild deter-
duced discoloring of stainless- gent.
steel exhaust systems can be re- Before operating the scooter
moved through polishing.) test its braking performance
3. To prevent corrosion, it is recom- and cornering behavior.
mended to apply a corrosion pro- 7
ECA10801
tection spray on all metal, NOTICE
including chrome- and nickel-plat-
Apply spray oil and wax spar-
ed, surfaces.
ingly and make sure to wipe off
4. Use spray oil as a universal clean-
any excess.
er to remove any remaining dirt.
Never apply oil or wax to any
5. Touch up minor paint damage
rubber and plastic parts, but
caused by stones, etc.
treat them with a suitable care
6. Wax all painted surfaces.
product.
7. Let the scooter dry completely be-
Avoid using abrasive polishing
fore storing or covering it.
compounds as they will wear
away the paint.
7-3
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SPECIFICATIONS
Dimensions: Engine oil: Cooling system:
Overall length: Recommended brand: Coolant reservoir capacity (up to the
2190 mm (86.2 in) YAMALUBE maximum level mark):
Overall width: Type: 0.31 L (0.33 US qt, 0.27 Imp.qt)
780 mm (30.7 in) SAE 10W-30, 10W-40, 10W-50, 15W-40, Radiator capacity (including all routes):
Overall height: 20W-40 or 20W-50 1.38 L (1.46 US qt, 1.21 Imp.qt)
1385 mm (54.5 in) Air filter:
0 10 30 50 70 90 110 130 ˚F
Seat height: Air filter element:
785 mm (30.9 in) SAE 10W-30 Oil-coated paper element
Wheelbase: Fuel:
SAE 10W-40
1565 mm (61.6 in) Recommended fuel:
Ground clearance: SAE 10W-50 Premium unleaded gasoline (Gasohol (E10)
103 mm (4.06 in) SAE 15W-40 acceptable)
Minimum turning radius: Fuel tank capacity:
SAE 20W-40
2500 mm (98.4 in) 14.0 L (3.70 US gal, 3.08 Imp.gal)
Weight: SAE 20W-50
Fuel reserve amount:
Curb weight: –20 –10 0 10 20 30 40 50 ˚C 2.0 L (0.53 US gal, 0.44 Imp.gal)
YP400R 211 kg (465 lb) Fuel injection:
Recommended engine oil grade:
YP400RA 215 kg (474 lb) Throttle body:
API service SG type or higher, JASO
Engine: ID mark:
standard MA
Engine type: 5RUG 20 8
Engine oil quantity:
Liquid cooled 4-stroke, DOHC Spark plug(s):
Without oil filter element replacement:
Cylinder arrangement: Manufacturer/model:
1.50 L (1.59 US qt, 1.32 Imp.qt)
Single cylinder NGK/CR7E
With oil filter element replacement:
Displacement: Spark plug gap:
1.70 L (1.80 US qt, 1.50 Imp.qt)
395 cm³ 0.7–0.8 mm (0.028–0.031 in)
Bore × stroke:
Final transmission oil:
Type: Clutch:
83.0 × 73.0 mm (3.27 × 2.87 in) Clutch type:
YAMALUBE 10W-40 or SAE 10W-30 type
Compression ratio: Dry, centrifugal automatic
SE motor oil
10.60 : 1 Transmission:
Quantity:
Starting system: Primary reduction ratio:
0.25 L (0.26 US qt, 0.22 Imp.qt)
Electric starter
1.000
Lubrication system: Final drive:
Wet sump Gear
8-1
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SPECIFICATIONS
Secondary reduction ratio: Loading: Operation:
6.643 (31/14 x 42/14) Maximum load: Right hand operation
Transmission type: YP400R 185 kg (408 lb) Specified brake fluid:
V-belt automatic YP400RA 181 kg (399 lb) DOT 4
Operation: (Total weight of rider, passenger, cargo Rear brake:
Centrifugal automatic type and accessories) Type:
Chassis: Tire air pressure (measured on cold Single disc brake
Frame type: tires): Operation:
Underbone Loading condition: Left hand operation
Caster angle: 0–90 kg (0–198 lb) Specified brake fluid:
28.00 ° Front: DOT 4
Trail: 220 kPa (2.20 kgf/cm², 32 psi) Front suspension:
100 mm (3.9 in) Rear: Type:
Front tire: 250 kPa (2.50 kgf/cm², 36 psi) Telescopic fork
Type: Loading condition: Spring/shock absorber type:
Tubeless YP400R 90–185 kg (198–408 lb) Coil spring/oil damper
Size: YP400RA 90–181 kg (198–399 lb) Wheel travel:
120/70-15 M/C 56S Front: 110.0 mm (4.33 in)
Manufacturer/model: 220 kPa (2.20 kgf/cm², 32 psi) Rear suspension:
MICHELIN/CITY GRIP Rear: Type:
Manufacturer/model: 250 kPa (2.50 kgf/cm², 36 psi) Unit swing
8
SAVA/DIAMONDS MC28 Front wheel: Spring/shock absorber type:
Rear tire: Wheel type: Coil spring/oil damper
Type: Cast wheel Wheel travel:
Tubeless Rim size: 92.0 mm (3.62 in)
Size: 15 x MT3.50 Electrical system:
150/70-13 M/C 64S Rear wheel: Ignition system:
Manufacturer/model: Wheel type: TCI
MICHELIN/CITY GRIP Cast wheel Charging system:
Manufacturer/model: Rim size: AC magneto
SAVA/DIAMONDS MC28 13 x MT4.00 Battery:
Front brake: Model:
Type: GT9B-4
Dual disc brake
8-2
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SPECIFICATIONS
Voltage, capacity: Headlight fuse:
12 V, 8.0 Ah 20.0 A
Headlight: Signaling system fuse:
Bulb type: 10.0 A
Halogen bulb Ignition fuse:
Bulb voltage, wattage × quantity: 10.0 A
Headlight: Radiator fan fuse:
12 V, 55.0 W × 2 7.5 A
Tail/brake light: Hazard fuse:
LED 10.0 A
Front turn signal light: ECU fuse:
12 V, 10.0 W × 2 10.0 A
Rear turn signal light: ABS control unit fuse:
12 V, 10.0 W × 2 YP400RA 10.0 A
Auxiliary light: ABS motor fuse:
LED YP400RA 30.0 A
License plate light: ABS solenoid fuse:
12 V, 5.0 W × 1 YP400RA 20.0 A
Meter lighting: Backup fuse:
12 V, 2.0 W × 3 10.0 A
High beam indicator light:
8
12 V, 1.4 W × 1
Turn signal indicator light:
12 V, 1.4 W × 2
Engine trouble warning light:
12 V, 1.4 W × 1
ABS warning light:
YP400RA 12 V, 1.4 W × 1
Immobilizer system indicator light:
LED
Fuses:
Main fuse:
30.0 A
8-3
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CONSUMER INFORMATION
EAU48613 EAU26411 EAU26461
The vehicle identification number is The model label is affixed to the loca-
stamped into the frame. tion shown. Record the information on
MODEL LABEL INFORMATION: this label in the space provided. This
TIP
information will be needed when order-
The vehicle identification number is
ing spare parts from a Yamaha dealer.
used to identify your vehicle and may
be used to register it with the licensing
authority in your area.
9
9-1
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INDEX
A Front fork, checking ............................. 6-28 S
ABS (for ABS models) .......................... 3-12 Front turn signal light ........................... 6-33 Safe-riding points ................................... 1-5
ABS warning light (for ABS models) ....... 3-4 Fuel ...................................................... 3-14 Safety information................................... 1-1
Acceleration and deceleration................ 5-3 Fuel consumption, tips for reducing ...... 5-4 Seat....................................................... 3-16
Air filter elements and check hoses Fuel tank cap........................................ 3-13 Shock absorber assemblies,
and V-belt case air filter element ....... 6-18 Fuses, replacing................................... 6-31 adjusting ............................................. 3-18
Anti-theft alarm (optional) ..................... 3-10 H Sidestand.............................................. 3-18
Auxiliary light ........................................ 6-35 Handlebar switches ............................. 3-10 Spark plug, checking............................ 6-11
B Hazard switch ...................................... 3-11 Specifications ......................................... 8-1
Battery .................................................. 6-29 Headlight bulb, replacing ..................... 6-32 Speedometer .......................................... 3-5
Brake fluid, changing............................ 6-26 High beam indicator light ....................... 3-4 Starting off .............................................. 5-2
Brake fluid level, checking.................... 6-24 Horn switch .......................................... 3-11 Starting the engine ................................. 5-1
Brake lever, front .................................. 3-11 I Start switch........................................... 3-11
Brake lever, rear ................................... 3-12 Identification numbers ........................... 9-1 Steering, checking ................................ 6-29
Brake levers, lubricating ....................... 6-27 Ignition circuit cut-off system .............. 3-19 Storage ................................................... 7-4
Braking ................................................... 5-3 Immobilizer system ................................ 3-1 Storage compartments......................... 3-16
C Immobilizer system indicator light ......... 3-4 T
Cables, checking and lubricating ......... 6-26 Indicator lights and warning lights ......... 3-3 Tachometer............................................. 3-6
Care ........................................................ 7-1 L Tail/brake light ...................................... 6-33
Catalytic converters.............................. 3-15 License plate light bulb, replacing ....... 6-34 Throttle grip and cable, checking and
Centerstand and sidestand, checking M lubricating........................................... 6-26
and lubricating ................................... 6-27 Main switch/steering lock ...................... 3-2 Throttle grip free play, checking ........... 6-20
Coolant ................................................. 6-16 Maintenance and lubrication, periodic... 6-4 Tires ...................................................... 6-21
D Maintenance, emission control Tool kit .................................................... 6-2
Dimmer switch...................................... 3-11 system ................................................. 6-3 Troubleshooting.................................... 6-35
E Matte color, caution ............................... 7-1 Troubleshooting charts......................... 6-36
Engine break-in ...................................... 5-4 Model label............................................. 9-1 Turn signal indicator lights...................... 3-3 10
Engine oil and oil filter element............. 6-13 Multi-function display............................. 3-6 Turn signal light bulb (rear),
Engine trouble warning light................... 3-4 P replacing............................................. 6-33
F Panels, removing and installing ............. 6-8 Turn signal switch................................. 3-11
Final transmission oil ............................ 6-15 Parking ................................................... 5-5 V
Front and rear brake lever free play, Part locations ......................................... 2-1 Valve clearance..................................... 6-20
checking............................................. 6-23 Pass switch .......................................... 3-11 Vehicle identification number ................. 9-1
Front and rear brake pads, checking ... 6-24
10-1
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INDEX
W
Wheel bearings, checking .................... 6-29
Wheels .................................................. 6-22
10
10-2
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MBK Industrie
Z.I. de Rouvroy 02100 Saint Quentin
PRINTED IN FRANCE
2013.09 (E)
DIC183