Yamaha 2004 YP400, Service Manual, Page: 80 / 417

3 - 1
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION CHART
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 10 20 30 40
1 *
Fuel line
(See page 3-29.)
• Check fuel hoses for cracks or damage.
√ √ √ √ √
2
Spark plug
(See page 3-17.)
• Check condition.
• Clean and regap.
√ √
• Replace.
√ √
3 *
Valves
(See page 3-10.) • Check valve clearance.
• Adjust.
Every 40,000 km
4
Air filter element
(See page 3-27.)
• Replace.
√ √
5
V-belt case air fil-
ter element
(See page 3-28.)
• Clean.
√ √ √ √
6 *
Front brake
(See pages 3-37,
38, 39.)
• Check operation, fluid level and vehicle for fluid
leakage.
√ √ √ √ √ √
• Replace brake pads. Whenever worn to the limit
7 *
Rear brake
(See pages 3-37,
38, 39.)
• Check operation, fluid level and vehicle for fluid
leakage.
√ √ √ √ √ √
• Replace brake pads. Whenever worn to the limit
8
Rear brake lock
(See page 3-36.) • Check operation.
• Adjust.
√ √ √ √ √ √
9 *
Brake hoses
(See page 3-38.)
• Check for cracks or damage.
√ √ √ √ √
• Replace. Every 4 years
10 *
Wheels
(See page 3-46.)
• Check runout and for damage.
√ √ √ √
11 *
Tires
(See page 3-43.)
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
√ √ √ √ √
12 *
Wheel bearings
(See page 4-4.)
• Check bearing for looseness or damage.
√ √ √ √
13 *
Steering bearings
(See page 3-40.)
• Check bearing play and steering for roughness.
√ √ √ √ √
• Lubricate with lithium-soap-based grease. Every 20,000 km
14 *
Chassis fasteners
(See page 2-21.) • Make sure that all nuts, bolts and screws are
properly tightened.
√ √ √ √ √
INTRODUCTION/
PERIODIC MAINTENANCE AND LUBRICATION CHART