🏷️ Basic Information Identification Make: Yamaha Model: XS400 Model Variants: XS400 Maxim, XS400 Special, XS400 Standard, XS400 Heritage Special, XS400SE, XS400SG, XS400SJ, XS400SK, XS400SL, XS400SN, XS400SP, XS400SR, XS400SS, XS400ST, XS400SU, XS400SV Production Years Covered By Manual: 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993 Codes Chassis Codes: 4G5, 2A2, 3A2, 12R, 55K, 50E, 48X, 21X, 22R, 5E8, 4R7, 5CU, 5GV, 5J8, 5R6, 5R8, 5RH, 5R7 👋 Introduction Market Position Positioning: Essential resource for Yamaha XS400 owners and mechanics seeking to perform their own maintenance and repairs. Competitive Analysis Value Proposition: Enables significant cost savings compared to professional servicing by providing expert, step-by-step guidance. Key Features Ease Of Use: Features easy-to-follow instructions and clear imagery to simplify complex procedures. Accessibility: Downloadable to PC, Mac, tablets, and smartphones for convenient access. Longevity: Permanent digital ownership, allowing for printing of specific sections or the entire manual. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Procedures Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhauls, Assembly, Disassembly Page Count Estimated Page Count: High (Detailed content for all years and models) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine: Top End Overhaul, Bottom End Rebuild, Valve Train, Camshafts, Crankshaft, Piston Assemblies, Cylinder Replacement, Oil System, Lubrication, Cooling System (Air-Cooled) Fuel System: Carburetor Synchronization, Rebuilding, Jetting, Fuel Pump (if applicable), Fuel Lines, Fuel Tank Servicing Ignition System: CDI Unit, Ignition Coils, Spark Plugs, Timing, Stator, Pickup Coils Transmission: Clutch Assembly, Gearbox Overhaul, Shift Drum and Forks, Sprockets, Chain Maintenance, Torque Specifications Brakes: Front and Rear Brake Caliper Service, Master Cylinder Rebuild, Brake Pad Replacement, Fluid Flush and Bleed, Rotor Inspection Suspension: Front Fork Overhaul (Oil Change, Seal Replacement), Rear Shock Absorber Service/Replacement, Swingarm Bushings Electrical System: Wiring Diagrams, Headlight, Taillight, Turn Signals, Battery Maintenance, Charging System (Alternator/Stator), Starter Motor, Switches, Fuses Chassis And Frame: Frame Inspection, Headstock Bearings, Wheel Bearings, Handlebar Replacement, Footpegs, Seat Mounting Bodywork And Trim: Fender Removal/Installation, Tank Mounting, Side Covers, Seat Removal, Instrument Cluster Servicing Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Chain Adjustment, Tire Pressure Checks, Brake Adjustments, Spark Plug Gapping/Replacement Troubleshooting: Diagnostic Flowcharts for Common Problems, Engine Performance Issues, Electrical Faults Engine Rebuild: Complete Engine Disassembly, Cleaning, Inspection, Measurement, Reassembly with Torque Specs Carburetor Service: Disassembly, Cleaning, Jet Replacement, Float Level Adjustment, Synchronisation Electrical Diagnostics: Continuity Testing, Voltage Checks, Resistance Measurements, Fault Finding on all electrical components Suspension Overhaul: Fork Seal Replacement, Fork Oil Change, Rear Shock Servicing Brake System Repair: Caliper Rebuild, Master Cylinder Service, Bleeding Procedure Assembly And Disassembly: Step-by-step instructions for all major components Technical Depth Depth: Comprehensive from basic user maintenance to full engine and transmission rebuilds Diagnostic Capabilities: Detailed troubleshooting guides and diagnostic procedures Specifications: Includes all critical torque values, clearances, measurements, and tolerances 📊 Manual Specifications File Format Format: PDF Searchability: Likely Searchable Text (depending on scan quality) Print Quality Quality: High Quality, intended for printing Binding Type Binding: Digital Downloadable (Printable by User) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: Air-cooled, 4-stroke, DOHC, Parallel-Twin Displacement: 392 cc (23.9 cu in) for most models, some later models might have 425cc variants. Exact displacement varies by chassis code. Common is 392cc. Bore X Stroke: Typically 69.0 mm x 51.4 mm (exact may vary slightly). Compression Ratio: Approximately 9.2:1 to 9.5:1 (varies by specific model/year). Performance Horsepower: Approximately 34-38 HP at 8000-8500 RPM (varies by model and tuning). Torque: Approximately 32-35 Nm (24-26 lb-ft) at 6000-7000 RPM (varies by model). Fuel System Carburetion: Dual Mikuni VM or BS series carburetors (e.g., VM34SC, BS34) Fuel Type: Unleaded gasoline Lubrication System Type: Wet sump with oil pump Engine Management Ignition: Transistor Controlled Ignition (TCI) / CDI 🔧 Transmission Standard Type: Constant Mesh, 6-speed sequential Optional Gearbox Features: Helical gears, all-up shift pattern Features Clutch Type: Wet, multiple-disc, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Length: Varies by model (e.g., XS400 Maxim ~2.1m) Width: Varies by model (e.g., XS400 Maxim ~0.8m) Height: Varies by model (e.g., XS400 Maxim ~1.15m) Weights Dry Weight: Approximately 165-180 kg (364-397 lbs) (varies by model). Wet Weight: Approximately 180-195 kg (397-430 lbs) (varies by model). 🛡️ Safety Features Ratings Safety Features: Dual Circuit Braking System, Reflectors, Hazard Lights (on some models). Active Features Active Safety: Responsive braking system, stable chassis geometry. Passive Features Passive Safety: Frame integrity, rider positioning for control. 💡 Technology Features Infotainment Infotainment Features: N/A (Analog instrumentation: Speedometer, Tachometer, Fuel Gauge, Indicator Lights). Driver Assistance Assistance Features: N/A (Focus on mechanical and electrical systems). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 km (or annually). Valve Check Interval: Every 10,000 - 15,000 km. Spark Plug Replacement: Every 10,000 - 15,000 km. Fluid Specifications Engine Oil Type: Yamalube (or equivalent) 10W-40 or 20W-40...