Yamaha XZ400 1985 User manual


*YAMAH A
A N
7,0
I~wl
C) () ,
SUPPLEMENTAR Y
OWNER'S
MANUAL
14X-28199-20


The
following arrangements
shouldbe made
in the XZ55ORJ (16R -28199-60) owner's manual
to
supersede
the
original corresponding por-
tions on the
pages
mentioned below .
XZ400 SUPPLEMENTAR Y
OWNER'S MANUA L
©1985
by
Yamaha Motor
Co .,
Ltd .
1st Edition, APRIL 198 5
All
rights
reserved .
Any reprinting
or
unauthorized use without the writte n
permission
of Yamaha Motor Co ., Ltd .
is
expressly prohibited .
Printed in
Japan


INTRODUCTIO N
Congratulations
on your purchase of the
Yamaha
XZ400 .
This model
represents
the
product
of
many
years
of Yamaha
experience
in the
production
of fine
sporting, touring,
and
pacesetting
rac-
ing motorcycles .
You can now
appreciate
the
high degree
of
craftsmanship
and
reliability
that
have madeYamaha leader in these fields . This
manual
will
provide you
with a
good
basic
understanding
of the features,
operation,basic
maintenance, and
inspection
items of this vehi-
cle . If
you have any questions regardingthe
operation
or maintenance of
yourmachine,
please
consult
a
Yamaha dealer .
-
NOTICE:
Some data in
this manual
may
become
out-dated due to
improvements
made to
the
motorcycle
in the
future .
If
there is
any question
concerning
this manual,
consult
yournearby
Yamaha dealer .
TECHNICAL PUBLICATIONS
SERVICE
DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR
CO.,
LTD .


&'A'I ;1I k[ e
PLEASE READ THIS MANUAL CAREFUL-
LY AND
COMPLETELY BEFORE OPERAT-
INGTHIS MOTORCYCLE .
Particularly important
information is distin-
guished
in this
manual
by
the
following
nota-
tions :
A WARNING indicates
special procedures
that
mustbe followed to avoid
injury
to a motor-
cycle operator
or
person inspecting or repair-
ing
the
motorcycle .
NOTE :
A NOTE
provides key
information
to make
pro-
cedures easier or clearer .
CAUTION :
A CAUTION indicates
special procedures
that
must be
followed to avoid
damage
to the
motorcycle .
IYAY1iIIJ[c

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Page
1-2
DESCRIPTION
1 . Brake fluid level windo w
2 . Fuel tank
ca p
3 .
Brake lever
4 . Brake
peda l
5 . Coolant reservoir tan k
6 . Fuse box


7.
Clutch lever
8 .
Engine
oil level windo w
9 . Fuel coc k
10.
Change peda l
11.
Batter y
12. Tool box
The
design
and
specification
of the
motorcy-
cle
you
have
purchased
may partly
differ from
those shown in the
photos
this manual carries .
-2 -


Page
9
Indicator
light
(Speed warning)"
indicator
light
(red) :
This
indicator
light
comes on at 80 km/h or
more.
irJiiwr n
(Speed warning)"
indicator
ligh t
I
5k/

. .
(
. .
j 
!
Page
1 1
Tachomete r
The tachometer
is
provided
so the rider
can
keep engine speed
within the ideal
power
range .
This model is
provided with
an electric
tachometer.
Do
not
operate
in
the red zone .
Red zone : 10,500 r/min and above
ITAi :III


Page
15 -17 Page 39,
Page
177 -179
"TURN"
signal
switch 
Adjustable
handlebars
This is a
three -way
switch : thecenter
position 
DELETE
is off ; turn to the "L"
to turn on the left flasher
and to the "R" for the
right flasher.
Be sure
to turn theswitch off after
completing
a turn .
1 . "TURN
switch
Page
39
Front fork s
The
front forks of this
model are
pneumo-
mechanical ;namely, a combination air and
mechanical coil
spring
in the inner tube
pro-
vides
suspension
best suitedto the
motorcy-
cle's load
(ex :
optional
accessories etc.)
and
riding
conditions
by
the
adjustment
of the air
pressure .


Always adjust
thefork
preload
tothe same
position
oneach side . Uneven
adjustment
can cause
poor
handling
and loss of
stability .
% '
IF
I
Page
181 -185
Front fork oil
change
1 . 
Fork oil
leakage
can cause loss of
stability
and safe
handling .
Have
any
problem
corrected before
operating
the
motorcycle .
2 . 
Securely support
the
motorcycle
so
there is no
danger
of it
falling
over .
1. Raise themotorcycle or remove the front
wheel so that
there is
no
weight
on the
front end of the
motorcycle .
2 .  Remove the wire holder,
pinch
bolts, and
handlebars .
1 . Wire holder 2. Pinch bolt
-5 --


3 .  Remove the air valve
caps
fromeach
cap
bolt .
Keep
the valve
open
while
pressing
it for
several seconds so that the air can
be let
out of the inner tube .
.
I
A
-14
~
I
1 . Push
4 . 
Remove the
cap
bolts from each inner
tube .

Ad o
1 .
Cap
bolt 
-6-
5 .  Place anopen
container under each drain
hole . Remove the drain screw fromeach
outer tube .
Do not allow oil to contact the
disc
brake
components .
If
any
oil
should contact the
brake
components
it
must
be
removed
before the
motorcycle
is
operated .
Oil will
cause diminished
braking capacity
and
will
damage
the rubber
components
of the
brake
assembly .
0 4
1 . Drain screw
ITATI :Il l[c


6 .  When most of the oil has drained,
slowly
raise and lower the outer tubes to
pump
out the
remaining
oil .
7 . 
Inspect
the drain screw
gasket . Replace
if
damaged .
Reinstall the drain screw .
8 .  Pour the
specified
amount of oil into the
fork
inner
tube .
Front fork oil (each fork):
272 cm3
(9.6
Imp
oz, 9 .2 US oz)
Fork Oil lOWt or
equivalent
9 .  After
filling, slowly pump
the forks
up
and
down to distribute the oil .
10 .
Inspect
the
0 -ring
on the cap bolt .
Replace 0 -ring
if
damaged .
11 . 
Tighten
the
cap
bolts.
Tightening torque :
23 Nm
(2 .3
m .kg,
17 ft .lb)
12 . If the air valve does notface towards the
front, loosen the
pinch
bolts on the under
bracket and reset the forks in the follow-
ing
procedure :
a .  Level the
top
of the inner fork tube with
thetop of the
steering
crown.
b . 
Face the
air valve towards
the
front.
44
'ALI '
71fr4


13 .  Install the handlebars and
tighten
the
pinch
bolts.
Torque
the bolts to
specifi-
cation .
Tightening torque :
Steering
crown -Inner tube :
20 Nm
(2.0
m .kg,
14 ft -lb)
Under bracket -Inner tube :
38 Nm
(3 .8
m .kg,
27 ft -lb )
14 . Install the wire holders .
15 . Fill the fork with air
using
a manual air
pump
or other pressurized air
supply .
Refer to "Front fork and rear shock ab-
sorber
adjustment"
for
proper
air
pressure
adjusting .
Maximum air
pressure :
245kPa
(2.5
kg
/cm2,36
psi)
Do not exceed
this amount .
Front fork
adjustmen t
1. Elevate the front wheel
by placing
the
motorcycle
on the centerstand .
NOTE :
When
checking
and
adjusting
the air
pressure,
there should beno
weight
on the front end of
the
motorcycle .

2 . 
Remove the air valve
cap
from thetop of
each fork.
3 . 
Using
the air check
gauge,
check and ad-
jsut
the
suspension
becomes stiffer and
if decreased, it becomes softer .
To increase :
Use a manual air
pump
or other
pressuriz-
ed air
supply.
To decrease :
Release the air
bypusning
the valve
pin.


NOTE :
100
Standard air
pressure:
39 .2 kPa
(0.4
kg/cm2,6 psi )
Maximum air
pressure :
245 kPa
(2 .5 kg
/cm2,36
psi )
Minimum air
pressure :
Zero
* 
Never exceed the maximum
pressure,
or oil seal
damagemay
occur .
* 
The difference between both
the left
and
right
tubes should be 9 .81 kPa
(0 .1
kg/cm2,
1 .4
psi)
or less .
An
optional
air check
gauge
is available. Please 4.
Install the air valve
caps securely.
askyournearby Yamaha dealer .
P/No . 2X4-2811A -00
-9 -
1 . Air checkgauge


Page
243-246
General
specifications
SPECIFICATION S
MODE L
Dimension :
Overall
lengt h
Overall widt h
Overall
heigh t
Wheelbas e
Minimum roadclearanc e
Basic
weight :
With oil and full fuel tan k
Performance :
Minimum
turning
radius :
Engine :
Type
Engine
model
Cylinder
Displacement
Bore >< Stroke
Compression
ratio
Startingsystem
Ignition
system
XZ40 0
2,145 mm (84 .4 in)
750 mm
(29 .5
in )
1,090 mm (42 .9 in )
1,455 mm
(57 .3
in)
135 mm (5 .3 in)
215
kg
(474 Ib )
2,700
mm
(106 .2
in )
4 stroke,
gasoline,
liquid
cooled, DOHC
14X
2 -cylinder V -type
398 cm
3
i
73.0x47.6 mm
(2.87x
1 .87 in)
10 .5 : 1
Electric starter
Battery ignition
(Full transistor
ignition)


MODE L
Fueltank
capacit y
Engine
oil
quantit y
Lubrication
syste m
Battery type/capacit y
Generato r
Spark plu g
Carbureto r
Air cleane r
Clutch
typ e
Transmission :
Primary
reduction
system
Primary
reduction ratio
Secondary
reduction
system
Secondary
reduction ratio
Gear box
type
Operation system
XZ40 0
Total : 17 L (3 .7
Imp gal,
4 .5 US
gal)
Reserve : 2 .7 L
(0 .6
Imp gal,
0 .7 US
gal)
Total amount : 3 .4 L (3 .0
Imp qt,
3 .6 US
qt)
Periodic oil
charge :2
.4 L
(2.1
Imp
qt,
2 .5 US
qt)
With oil filter
replacement :
2 .7 L
(2 .4
Imp qt,
2 .9 US
qt)
Wet
sum p
YB14L/12V, 14A H
AC .
magnet o
D8EA/NGK, X24ES -U/NIPPONDENSO
BD34x 2
Dry type
elemen t
Wet,
multiple-dis c
Gea r
74/31 (2.387 )
Shaf t
19/18x32/11
(3 .070 )
Constant mesh,
5 -speed
forwar d
Left foot
operatio n
-11 -


MODEL XZ40 0
Gear ratio : First 43/15
(2.866 )
Second 39/20 (1.950 )
Third 31/21
(1.476 )
Fourth 32/27 (1.185 )
Fifth
29/29 (1.000 )
Chassis :
Frame
type
Pressed backbon e
Steering :
Caster 26°20 '
Trail 116 mm
(4 .57
in)
Tire size :
Front 90/90-18 51 S
Rear 110/90-1861 S
Braking system :
Front Disc
brake/Right
hand
operatio n
Rear Drum
brake/Right
hand
operatio n
Suspension :
Front
Telescopic
for k
Rear
Swing
ar m
(Monocross
suspension
'De Carbon"
system )
Shock absorber :
Front Air/coil
spring,
oil
dampe r
Rear Gas/coil
spring,
oil
dampe r
-12 - -


MODEL
XZ400
Electrical :
Headlight
12V, 60W/55W
(Quartz
bulb)
Tail/brake
light
12V, 8W/27W x2
Flasher
light
12V, 27Wx 4
Auxiliary light
12V, 3 .4 W
License
light
12V, 3 .4Wx 2
Pilot
lights :
TURN 12V, 3 .4Wx 2
OIL 12V, 3 .4 W
NEUTRAL 12V, 3 .4 W
HIGH
BEAM
12V,
3 .4 W
(Speed
warning)
12V, 3 .4 W
Meter
light
12V, 3.4Wx 2
-13--


YAMAHA
MOTOR
CO .,LTD .
MATA,JAPAN
PRINTED IN JAPA N
854 -O.3x1
0
( )
41