1977-1981 Yamaha XS360 XS400 Motorcycle Service Manual

Description

This 275 page, high quality reproduction of the original out of print 1977-1981 Yamaha XS360 XS400 Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for Yamaha XS400H/SH motorcycles.

This 1977-1981 Yamaha XS360 XS400 Service Manual covers the following motorcycles:

1981 Yamaha XS400SJ Heritage
1981 Yamaha XS400SH Heritage
1981 Yamaha XS400H Special II
1980 Yamaha XS400SG Special
1980 Yamaha XS400G Special II
1979 Yamaha XS400SG Special
1979 Yamaha XS400G Special II
1979 Yamaha XS400F
1979 Yamaha XS4002F
1978 Yamaha XS400E
1978 Yamaha XS4002E
1977 Yamaha XS400D
1977 Yamaha XS3602D

Table of Contents

General Information
Model Identification
Special Tools

Periodic Inspections and Adjustments
MAINTENANCE AND LUBRICATION CHART
ENGINE
Carburetor
Air Filter
Float Level
Engine Oil
Engine Oil and Filter Replacement
Clutch Adjustment
Valve Clearance Adjustment
Cam Chain Adjustment
CHASSIS
Fuel Petcock
Front Brake and Wheel
Rear Brake and Wheel
Drive Chain Tension Check
Drive Chain Tension Adjustment
Drive Chain Lubrication
Front Fork Oil Change
Suspension, Steering and Swing Arm
ELECTRICAL
Ignition Timing
Spark Plug
Battery
Headlight

Engine Overhauling
REMOVAL
Preparation for Removal
Removal
DISASSEMBLY
Cylinder Head Cover
Cylinder Head
Cylinder
Piston Pin and Piston
Kick Crank
Crankcase Cover (R)
Clutch Assembly and Drive Gear
Crankcase Cover (L)
Oil Strainer Assembly
Crankcase
INSPECTION AND REPAIRING
Cylinder Head Cover
Cylinder Head
Valve, Valve Springs, Valve Guides and Valve Seats
Camshaft and Sprocket
Cylinder
Piston and Piston Rings
Piston Pin
Crankshaft
Oil Pump
Primary Drive
Clutch
Transmission
Kick Starter
Bearings and Oil Seals
Neutral Switch
Crankcase
ENGINE ASSEMBLING AND ADJUSTMENT
Transmission and Shifter Installation
Crankshaft Installation
Crankcase
Crankcase Cover (L)
Piston
Cylinder
Cylinder Head
Camshaft and Sprocket
Cylinder Head Cover
Drive Sprocket
Contact Breaker
Kick Starter Assembly
Clutch
Oil Pump
Crankcase Cover
Oil Strainer
MOUNTING

Carburetion
Disassembly
Float Level Adjustment

Chassis
FRONT WHEEL
Removal
Front Axle
Replacing Wheel Bearings
Front Wheel Installation
REAR WHEEL
Removing the Rear Wheel
Checking Brake Shoe Wear
Brake Drum
Brake shoe Plate
Replacing Wheel Bearings
Installing Rear Wheel
DISC BRAKES
Disc Brake Disassembly
Disc Brake Inspection
Disc Brake Assembly
RIM AND SPOKES
Checking for Loose Spokes
TIRES AND TUBES
Removal
Inspection
DRIVE CHAIN AND SPROCKETS
Drive Sprocket
Driven Sprocket
Chain Inspection
Chain Maintenance
FRONT FORKS
Disassembly
Assembly
STEERING HEAD
Adjustment
Disassembly
Inspection
Installation
SWING ARM
Swing Arm Inspection
Swing Arm Lubrication
Swing Arm Removal
REAR SHOCK ABSORBER
Removal
Inspection
CABLES AND FITTINGS
Cable Maintenance

Electrical
Ignition System
Ignition Timing
Spark Gap Test
Ignition Coil
Condenser Test
Spark Plug
Charging System
AC Generator
Regulator
Checking Silicon Rectifier
Battery
Checking
Service Life
Storage
Starter Motor
Servicing and Troubleshooting
Lighting and Signal System
Lighting Tests and Checks
Flasher Self Canceling System