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Yamaha XS400 1979 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XS400 Year: 1979 Type: Motorcycle Codes Model Code: XS400-E 👋 Introduction Market Position Target Audience: Professional Technicians and DIY Mechanics Competitive Analysis Value Proposition: Comprehensive repair information, instant download, cost savings over physical manuals Key Features Accessibility: Instant Download, No Shipping Costs Usability: Numbered Table of Contents, Bold Figure Numbers for easy referencing 📋 Manual Details Coverage Areas Scope: Full Service Repair Page Count Estimated Page Count: Varies (Typical for this era ~200-400 pages) Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, carburetor servicing, ignition system diagnosis Transmission: Clutch operation, gearbox maintenance, shifting mechanism Electrical: Wiring diagrams, charging system, lighting, ignition components, starter system Chassis: Frame inspection, suspension (front fork, rear shocks), steering system Brakes: Front and rear brake system maintenance, hydraulic components, adjustment Fuel System: Fuel tank, fuel lines, petcock, carburetor synchronization and adjustment Exhaust: Exhaust system inspection and servicing Wheels And Tires: Wheel bearing maintenance, tire pressure, wheel removal and installation Cooling System: Air intake and cooling fin cleaning procedures Bodywork: Seat removal, fuel tank mounting, fender inspection, side cover servicing Lubrication System: Oil pump servicing, oil filter replacement, oil gallery inspection Procedures Included Maintenance: Scheduled maintenance, lubrication, fluid changes, filter replacement Repair: Engine rebuild, transmission repair, electrical fault finding, suspension overhaul Troubleshooting: Diagnostic procedures for common and uncommon faults, electrical troubleshooting charts Rebuilding: Detailed instructions for component rebuilds (e.g., engine, carburetors, brake calipers) Refurbishment: Guidance on restoring components to original specifications Diagnostics: Electrical system diagnostics, performance troubleshooting Wiring Diagrams: Detailed, integrated with electrical troubleshooting Specifications: Torque specifications for all major fasteners, clearances, tolerances Service Schedules: Preventative maintenance schedules for various mileages and time intervals Technical Depth Level: Comprehensive (Professional Technician Level) Detail Level: Detailed sub-steps, notes, cautions, warnings, numbered instructions Illustrations: Detailed illustrations, drawings, photos, enlarged insets 📊 Manual Specifications File Format Compatibility: All versions of Windows & Mac Print Quality Printability: Full Printable (All pages) Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Storage: Savable to hard-drive, burnable to CD-ROM Requirements Software Requirements: Adobe PDF Reader & WinRAR ⚙️ Engine Specifications Primary Engine Configuration: Parallel-Twin, Four-Stroke Displacement: 392 cc (approx.) Bore X Stroke: 64.0 mm x 62.0 mm (typical for XS400 variants) Compression Ratio: 9.2:1 (typical) Cooling System: Air-cooled Valve Train: DOHC (Double Overhead Camshafts), 2 Valves per Cylinder Performance Horsepower: Approximately 27-30 HP (at crank) Torque: Approximately 22-24 lb-ft (at crank) Fuel System Carburetors: Dual Mikuni VM34 (or similar constant velocity carburetors) Fuel Delivery: Gravity feed from fuel tank via petcock Ignition Ignition Type: Electronic Ignition (CDI) Lubrication Oil Type: SAE 20W-40 or 10W-40 API SE classification motorcycle oil (refer to manual for precise recommendation) Oil Capacity: Approximately 2.2-2.5 liters (including filter change) 🔧 Transmission Standard Type: Constant Mesh, 5-Speed Sequential Features Clutch: Wet Multi-Plate Clutch Drive Type: Shaft Drive 📐 Dimensions Exterior Wheelbase: Approximately 55.5 inches (1410 mm) Weights Dry Weight: Approximately 370 lbs (168 kg) 🛡️ Safety Features Ratings Safety Standards: N/A (Era specific, emphasis on mechanical reliability) Active Features Braking System: Front: Disc Brake, Rear: Drum Brake Passive Features Lighting: Headlight, Tail Light, Turn Signals 💡 Technology Features Infotainment Features: N/A (Analog instrumentation: speedometer, tachometer, odometer, indicator lights) Driver Assistance Features: N/A (No electronic rider aids common in this era) 🔧 Maintenance Service Intervals Oil Change: Every 3,000 miles or 6 months (typical, refer to manual for specifics) Spark Plug Check: Every 6,000 miles (typical) Valve Clearance Check: Every 12,000 miles (typical) Fluid Specifications Brake Fluid: DOT 3 or DOT 4 (refer to manual for precise specification) Fork Oil: Typically SAE 10W fork oil, capacity approx. 180-190cc per fork leg (refer to manual) Known Issues Common Problems: Carburetor synchronization drift, electrical connector corrosion, worn output shaft seal, aging rubber components (hoses, mounts) 📚 Vehicle History Brand Heritage Manufacturer Origin: Japan Model Evolution Xs Series Context: Part of Yamaha's successful XS line, known for reliable parallel-twin engines Production Production Period: Late 1970s to early 1980s
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Yamaha XS400 1979 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XS400
Year:
1979
Type:
Motorcycle
Codes
Model Code:
XS400-E
👋 Introduction
Market Position
Target Audience:
Professional Technicians and DIY Mechanics
Competitive Analysis
Value Proposition:
Comprehensive repair information, instant download, cost savings over physical manuals
Key Features
Accessibility:
Instant Download, No Shipping Costs
Usability:
Numbered Table of Contents, Bold Figure Numbers for easy referencing
📋 Manual Details
Coverage Areas
Scope:
Full Service Repair
Page Count
Estimated Page Count:
Varies (Typical for this era ~200-400 pages)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, tuning, carburetor servicing, ignition system diagnosis
Transmission:
Clutch operation, gearbox maintenance, shifting mechanism
Electrical:
Wiring diagrams, charging system, lighting, ignition components, starter system
Chassis:
Frame inspection, suspension (front fork, rear shocks), steering system
Brakes:
Front and rear brake system maintenance, hydraulic components, adjustment
Fuel System:
Fuel tank, fuel lines, petcock, carburetor synchronization and adjustment
Exhaust:
Exhaust system inspection and servicing
Wheels And Tires:
Wheel bearing maintenance, tire pressure, wheel removal and installation
Cooling System:
Air intake and cooling fin cleaning procedures
Bodywork:
Seat removal, fuel tank mounting, fender inspection, side cover servicing
Lubrication System:
Oil pump servicing, oil filter replacement, oil gallery inspection
Procedures Included
Maintenance:
Scheduled maintenance, lubrication, fluid changes, filter replacement
Repair:
Engine rebuild, transmission repair, electrical fault finding, suspension overhaul
Troubleshooting:
Diagnostic procedures for common and uncommon faults, electrical troubleshooting charts
Rebuilding:
Detailed instructions for component rebuilds (e.g., engine, carburetors, brake calipers)
Refurbishment:
Guidance on restoring components to original specifications
Diagnostics:
Electrical system diagnostics, performance troubleshooting
Wiring Diagrams:
Detailed, integrated with electrical troubleshooting
Specifications:
Torque specifications for all major fasteners, clearances, tolerances
Service Schedules:
Preventative maintenance schedules for various mileages and time intervals
Technical Depth
Level:
Comprehensive (Professional Technician Level)
Detail Level:
Detailed sub-steps, notes, cautions, warnings, numbered instructions
Illustrations:
Detailed illustrations, drawings, photos, enlarged insets
📊 Manual Specifications
File Format
Compatibility:
All versions of Windows & Mac
Print Quality
Printability:
Full Printable (All pages)
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Storage:
Savable to hard-drive, burnable to CD-ROM
Requirements
Software Requirements:
Adobe PDF Reader & WinRAR
⚙️ Engine Specifications
Primary Engine
Configuration:
Parallel-Twin, Four-Stroke
Displacement:
392 cc (approx.)
Bore X Stroke:
64.0 mm x 62.0 mm (typical for XS400 variants)
Compression Ratio:
9.2:1 (typical)
Cooling System:
Air-cooled
Valve Train:
DOHC (Double Overhead Camshafts), 2 Valves per Cylinder
Performance
Horsepower:
Approximately 27-30 HP (at crank)
Torque:
Approximately 22-24 lb-ft (at crank)
Fuel System
Carburetors:
Dual Mikuni VM34 (or similar constant velocity carburetors)
Fuel Delivery:
Gravity feed from fuel tank via petcock
Ignition
Ignition Type:
Electronic Ignition (CDI)
Lubrication
Oil Type:
SAE 20W-40 or 10W-40 API SE classification motorcycle oil (refer to manual for precise recommendation)
Oil Capacity:
Approximately 2.2-2.5 liters (including filter change)
🔧 Transmission
Standard
Type:
Constant Mesh, 5-Speed Sequential
Features
Clutch:
Wet Multi-Plate Clutch
Drive Type:
Shaft Drive
📐 Dimensions
Exterior
Wheelbase:
Approximately 55.5 inches (1410 mm)
Weights
Dry Weight:
Approximately 370 lbs (168 kg)
🛡️ Safety Features
Ratings
Safety Standards:
N/A (Era specific, emphasis on mechanical reliability)
Active Features
Braking System:
Front: Disc Brake, Rear: Drum Brake
Passive Features
Lighting:
Headlight, Tail Light, Turn Signals
💡 Technology Features
Infotainment
Features:
N/A (Analog instrumentation: speedometer, tachometer, odometer, indicator lights)
Driver Assistance
Features:
N/A (No electronic rider aids common in this era)
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 miles or 6 months (typical, refer to manual for specifics)
Spark Plug Check:
Every 6,000 miles (typical)
Valve Clearance Check:
Every 12,000 miles (typical)
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for precise specification)
Fork Oil:
Typically SAE 10W fork oil, capacity approx. 180-190cc per fork leg (refer to manual)
Known Issues
Common Problems:
Carburetor synchronization drift, electrical connector corrosion, worn output shaft seal, aging rubber components (hoses, mounts)
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Model Evolution
Xs Series Context:
Part of Yamaha's successful XS line, known for reliable parallel-twin engines
Production
Production Period:
Late 1970s to early 1980s
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