1977-1982 Yamaha XS400 Service Manual

Technician-level documentation for the 1977-1982 Yamaha XS400, covering engine, chassis, electrical, and FI systems. Publication Part No. 41X-28197-00.

4.5starstarstarstarstar_half(4)
visibility Preview Available
Suzuki 1977-1982 Yamaha XS400 Service Manual manual page preview - page 1 of

Sample pages from the 1977-1982 Yamaha XS400 Service Manual manual

Suzuki 1977-1982 Yamaha XS400 Service Manual manual preview page 1 - thumbnail
Suzuki 1977-1982 Yamaha XS400 Service Manual manual preview page 5 - thumbnail
info_outline Click thumbnails to preview different pages

Purchase & Download

$16.40 (incl. VAT) Instant Download / No Shipping Fees
1 sold in the last 30 days
OR BUY NOW
verified_user
Lifetime Access
Re-download anytime
flash_on
Instant Download
Get it immediately
lock
Secure Payment
PayPal

Document Details

keyboard_arrow_down
Document Number / Seller:
30114 / Matthew Bell
File Size:
34.21 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Aug 11, 2025

Models Covered & Key Technical Specifications

Yamaha XS400 (41X-28197-00) - 1977-1982

Factory Repair Manual | Reference Kit.

  • Design Specifications: Dimensional Limits: 0.10 mm establishes the minimum gap allowance for tappets in cold operation.
  • Advanced Tuning Parameters: For optimal performance, 2.0-4.0mm defines the throttle cable play range.
  • Calibrated Inspection Data: Documented Procedures: 12,000 km signifies the interval for spark plug replacement.
  • Documented Maintenance Schedules: Prescribed Intervals: 6,000 km indicates the service interval for air filter inspection.
  • Prescribed Operational Guidelines: Engineered Specifications: 1.1 kgf-m represents the torque for spark plugs.
  • Engineered Performance Metrics: Calibrated Values: 100 N-m denotes the rear axle nut torque for E-03, 28, 33 models.

Professional Workshop Service Manual & Technical Specifications

Yamaha XS400 FI System Manual: Yamaha Official Service & Repair Manual - 1977-1982 Edition Manual-Nexus

Equipment-Series: FI System | Technical-Scope: FI System Logic | Equipment-Series: Motorcycle Mechanics.

TABLE OF CONTENTS

Integrated-Framework Diagnostic-Logic Calibration-Data
Precautions in Servicing FI System Technical Features Crankshaft Position Sensor (CKP Sensor)
Connector/Coupler Injection Time (Injection Volume) Camshaft Position Sensor (CMP Sensor)
ECM/Various Sensors Fuel Delivery System Intake Air Temperature Sensor (IAT Sensor)
Self-Diagnosis Function Fuel Pump Control System Engine Coolant Temperature Sensor (ECT SENSOR)
TPS Adjustment Sensors Atmospheric Pressure Sensor (AP Sensor)

TABLE OF CONTENTS SUMMARY

Outlining the operational framework across: Precautions in Servicing, FI System Technical Features, Connector/Coupler, ECM/Various Sensors, and Self-Diagnosis Function. This manual meticulously documents the intricacies of the motorcycle's fuel injection system. Calibration requirements are specified for sensor voltage ranges to ensure accurate readings. Electrical circuit inspection procedures are thoroughly detailed, utilizing specialized testers for diagnostic accuracy. Wear limits are specified for critical components, guiding timely replacement to maintain peak engine performance. Fuel injector specifications are provided, detailing operation and maintenance. The manual also covers essential troubleshooting steps for common FI system malfunctions, including specific error codes and their solutions. Torque specifications are included for critical fasteners related to the FI system, ensuring proper assembly and function.

This document details the fuel pump's operation, including its control system and potential issues. It provides comprehensive coverage of all sensors within the FI system, explaining their function, location, and testing procedures. Troubleshooting sections offer step-by-step guidance for diagnosing and resolving malfunctions indicated by the ECM, ensuring a smooth and reliable riding experience.

FAQ

What are the **proper** clearance measurements for the Yamaha XS400? keyboard_arrow_down

0.10 - 0.20 mm is the specified clearance for intake tappets when the engine is cold.

Specify the **standard** torque specifications for the Yamaha XS400. keyboard_arrow_down

1.1 kgf-m is the standard torque specification for the spark plugs.

What is the **necessary** safety precaution when working with the FI system? keyboard_arrow_down

11 V is the minimum battery voltage required for accurate measurements when testing electrical components.

Customer Reviews

Read what our customers say about this Suzuki Motorcycle manual and share your own experience.

Add a Review

* Required information
1000
Captcha Image

Reviews (4)

Avatar
New
Rated 4 out of 5 stars
Avatar
New
This manual is incredibly detailed and has everything I needed to maintain my bike. The download process was smooth, and the customer support was very responsive!
Avatar
New
I found this service manual to be comprehensive and easy to follow. I appreciated the quick email response when I had questions about the download. Highly recommend!
Avatar
New
The manual is well-structured and covers all necessary repairs. Plus, the download link was sent promptly after purchase. Excellent service!