1982 Yamaha XS400 Motorcycle Service Manual
1982 Yamaha XS400 motorcycle documentation with in-depth coverage of engine, chassis, and electrical systems. Includes diagrams and troubleshooting. Part Number: 12E-28197-80
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Sample pages from the 1982 Yamaha XS400 Motorcycle Service Manual manual
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Yamaha Models Covered & Key Technical Specifications
Models: Yamaha XS400
Build Years: 1982
Serial Numbers: 12E-000101 and up
Technical Data:
- Engine idle speed: 1,200 ± 50 r/min
- Standard spark plug: DR8ES-L
- Spark plug gap: 0.6–0.7 mm (0.023–0.028 in)
- Spark plug torque: 20 Nm (14.5 ft-lb)
- Compression pressure (standard): 980 kPa (142.2 psi)
- Compression pressure (minimum): 785 kPa (113.8 psi)
- Compression pressure (maximum): 1,079 kPa (156.4 psi)
- Intake valve clearance (cold): 0.11–0.15 mm (0.004–0.006 in)
- Exhaust valve clearance (cold): 0.16–0.20 mm (0.006–0.008 in)
- Drive chain deflection: Approximately 30 mm (1.2 in)
- Front fork oil capacity: 263 cm³ (8.9 US oz)
- Rear wheel axle torque: 105 Nm (75 ft-lb)
- Oil drain plug torque: 43 Nm (31.0 ft-lb)
- Oil filter bolt torque: 15 Nm (11.0 ft-lb)
Yamaha Manual Features & Content Preview
1982 Yamaha XS400 Official Service Manual
- This 317-page 1982 Yamaha XS400 factory service manual covers the 12E-series engine overhaul, chassis maintenance, and electrical system diagnostics
- Official Yamaha publication 12E-28197-80
- Contains dozens of technical exploded-view diagrams, torque specification tables, and valve shim selection charts for precision engine assembly
- Delivered as a direct download the moment payment clears
- Indexed PDF search covers every chapter and appendix
- Detailed engine identification and serial number tracking for the 1982 model year
- This official 1982 Yamaha XS400 manual remains the authoritative technical reference for the 12E-series chassis and drivetrain assembly, offering accurate torque values and clearances for professional-level engine restoration
Documentation Walkthrough
This comprehensive guide organizes maintenance and diagnostic information into seven distinct sections. The general information section details engine and frame identification codes, while the periodic maintenance chapter defines service intervals for lubrication, valve clearances, and chain tension. Subsequent chapters detail major component tear-downs, including complete engine overhauls with detailed piston, cylinder, and camshaft removal steps. The manual continues with dedicated sections for carburetor system synchronization, chassis alignment, and detailed electrical component testing.
Technical Specification Preview
This publication contains extensive technical data required for precise equipment setup and maintenance. Engine specifications are listed for valve clearances, cylinder compression pressures, and oil filter bolt torque values of 15 Nm. Electrical system data includes charging requirements of 1.2 amps for 10 hours and headlight beam adjustment procedures. Chassis data documents specific torque values for the rear axle at 105 Nm, along with drive chain deflection limits of 30 mm for safe operation. For more details, refer to what an OEM service publication covers to understand how factory documentation is structured for vintage motorcycle maintenance. Valve clearance for the intake is listed at 0.11–0.20 mm in the cylinder head specification table. Compression pressure for the 1982 Yamaha XS400 is documented as 980 kPa at sea level. The rear brake adjustment range is specified at 20–30 mm. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. An official 317-page Yamaha OEM workshop manual covering the 1982 XS400, documenting engine, chassis, electrical, and carburetor specifications for the 12E-series build.
Document Reference: 12E-28197-80
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