Yamaha · Yamaha XS-1 / XS650 (1970-1985)

XS250 / XS360 / XS400 twin

Library entry covers 1976-1984

24 factory 46 guideline

Published source

Yamaha XS400 Service Manual (1982), Chapter 2 Periodic Inspections and Adjustments: A. Periodic Maintenance p.2-2, B. Lubrication Intervals p.2-3

Factory service manual. Covers 1982 XS400 (DOHC) factory service manual; closest factory schedule found for the earlier SOHC XS250/360/400, whose own charts may differ; chart in km with miles.

Open the source

70 items for a 1976 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1976 Yamaha XS250 / XS360 / XS400 twin

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain: check tension, alignment/adjust as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain: lube/adjust as required (SAE 10W30 motor oil). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 2,000 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Factory

Manual: Lights/signals: check operation/replace as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)
Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Fittings/fasteners: tighten before each trip and/or as listed. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)

Every 1,000 mi or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 1,000 mi

1 item

Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (dry type): clean/replace as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3

Every 2,000 mi

12 items

Change engine oil

Engine

Factory

Manual: Engine oil: replace (warm engine before draining). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs: inspect/clean or replace as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Fuel cock: clean/flush tank as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 and 1,500 km
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor: check operation/adjust as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 3,000 km (2,000 mi)
Check / set ignition timing

Ignition and electrics

Factory

Manual: Ignition timing: check/repair as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 1,500 km (1,000 mi)
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: top-up/check specific gravity and breather pipe. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: check/adjust as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain: remove/clean/lube. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 1,500 km (1,000 mi)
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Factory

Manual: Brake and change pedal shaft, brake and clutch lever pivot: apply lightly (SAE 10W30). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 1,500 km (1,000 mi)
Check brake pads and discs

Brakes

Factory

Manual: Brake system (complete): check/adjust as required, repair as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 1,500 km (1,000 mi)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Wheel and tires: check pressure/wear/balance/damage. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 and 1,500 km
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control/meter cables: apply thoroughly (SAE 10W30); throttle grip/housing: lithium grease. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 1,500 km (1,000 mi)

Every 3,000 mi or 12 months

14 items

Adjust cam chain tensioner

Engine

Guideline
Check engine mounting bolts and plates

Engine

Guideline
Clean oil strainers / mesh screens

Engine

Guideline

Often done with every oil change on old machines.
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

2 items

Replace spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 4,000 mi

5 items

Check and adjust valve clearances

Engine

Factory

Manual: Valves: check/adjust valve clearance. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 1,500 km (1,000 mi) and 3,000 km (2,000 mi)
Compression test (or leak-down)

Engine

Factory

Manual: Cylinder(s): check compression. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 3,000 km (2,000 mi)
Replace oil filter

Engine

Factory

Manual: Oil filter element: clean or replace as required. Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 500 km (300 mi)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot shaft: apply lightly (lithium grease). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 3,000 km (2,000 mi)
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Factory

Manual: Speedometer gear housing: inspect thoroughly/pack moderately (lithium grease). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: first at 3,000 km (2,000 mi)

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline

Every 6,000 mi or 2 years

2 items

Check engine breather and oil return

Engine

Guideline
Lubricate and check automatic advance unit

Ignition and electrics

Guideline

Every 8,000 mi or 12 months

1 item

Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings: inspect thoroughly, repack (medium-weight wheel bearing grease). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3: yearly or 12,000 km

Every 8,000 mi

1 item

Change fork oil

Front end

Factory

Manual: Front forks: drain completely, refill (SAE 10W30 type SE). Factory: Periodic maintenance p.2-2 / lubrication intervals p.2-3

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

4 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.