Yamaha LIT-11616-16-02, 5TE-F8197-10 service manual Driv

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FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

DRIV

Order	Job name/Part name	Q’ty	Remarks

C	Shim (right)
D	Circlip/bearing	1/1
E	Drive pinion gear	1
F	Differential gear case	1
			For assembly, reverse the disassembly
			procedure.

7 - 8

Image 236

Contents YFM400FAR YFM400FAR Important Information Exploded Diagrams Manual OrganizationGEN Spec Info CHK ENG ADJ Table of Contents Contents Chapter General Information Fuel Tank IntroductionSeat and Side Panels Chapter Engine Page Chapter Cooling System Troubleshooting Rear AXLE/FINAL Drive Gear and Drive ShaftChapter Chassis Chapter Electrical Front Arms and Front Shock AbsorbersFaulty Drive Train Faulty Gear ShiftingFaulty Clutch Performance Starting FAILURE/HARD StartingFaulty Brake OverheatingPoor Braking Effect MalfunctionVehicle Identification Number Model LabelGASKETS, OIL Seals and O-RINGS Preparation for Removal ProceduresReplacement Parts Circlips Lock WASHERS/PLATES and Cotter PinsBearings and OIL Seals Checking of Connections Tool No Tool name/How to use Illustration Crankshaft installer set Sheave fixed block Compression gauge Clutch holding tool General Specifications Maxxis MikuniDR8EA/NGK YTX14AH Engine Seat Width Margin Thickness Head Diameter Face Width 41.27 mm Spec Spec Spec Pressure feed Splashed scavenge Camshaft Crank Pin Standard Limit Cylinder head tightening sequence Tightening torques Neutral switch M10 Reverse switch Stator assembly Chassis DOT Tightening torques Spec Electrical 5ND/NIPPON Thermostat MS5F-561/JIDECO4BA/DENSO Metric Multiplier Imperial Conversion TableLubrication Points and Lubricant Types Coolant Flow Diagrams Radiator Thermostat To coolant reservoir OIL Flow Diagrams Oil filter Oil pump Oil strainer Cable Routing Spec Spec Spec Spec Spec Spec Spec Spec Spec Introduction CHK ADJ Seat and Side Panels Removing the seat and side panelsBumper and front fender Front CARRIER, Front Bumper and Front FenderRemoving the front carrier, front CHK ADJ Rear Carrier and Rear Fender Removing the rear carrier and rearFender First disconnect the negative leadCHK ADJ Bumper and Front Fender Fuel TankRemoving the fuel tank Removing the footrest boards Adjusting the Valve Clearance Adjusting the Valve Clearance Locknut 20 Nm 2.0 m kg, 14 ft lb Adjustment stepsTappet adjusting tool YM-08035 Adjusting the Idling Speed Engine idling speed 1,450 ~ 1,550 r/minThrottle lever free play ~ 5 mm 0.12 ~ 0.20 Adjusting the Throttle Lever Free PlayTurning Idling speed becomes Higher Turning out Lower Adjustment steps First step Speed limiter length 12 mm 0.47 Adjusting the Speed LimiterSecond step Speed limiter length adjustment steps Adjusting the Starter CableStarter plunger stroke distance 15 mm 0.59 Spark plug gap ~ 0.7 mm 0.024 ~ 0.028 Checking the Spark PlugStandard spark plug DR8EA/NGK Checking the Ignition Timing Engine speed 1,450 ~ 1,550 r/minRecoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib LoctiteMeasuring the Compression Pressure Compression gauge YU-33223 Adapter YU-33223-3Measuring the Compression Pressure Do not allow foreign material to enter the crankcase Recommended oil Follow the left chartChecking the Engine OIL Level Oil filter wrench YU-38411 Replacement stepsChanging the Engine OIL Cautio N Oil filter cartridge 17 Nm 1.7 m kg, 12 ft lbCleaning the AIR Filter Oil gallery bolt Nm 0.7 m kg, 5.1 ft lbCleaning the AIR Filter Cleaning steps Checking the Coolant Level Changing the Coolant 10 Nm 1.0 m kg, 7.2 ft lb CHK ADJ Belt width 30.7 mm 1.21 in Limit 27.6 mm 1.09 Checking the Coolant TemperatureChecking the V-BELT Replacing steps Cleaning the Spark Arrester Rear brake pedal free play 20 ~ 30 mm 0.8 ~ 1.2 Adjusting the Rear BrakeRear brake pedal free play 20 ~ 30 mm 0.80 ~ 1.18 Gap a ~ 1 mm 0.00 ~ 0.04 DOT Checking the Front Brake Fluid LevelRecommended brake fluid Checking the Rear Brake Shoes Checking the Front Brake PadsBrake pad wear limit a 1 mm 0.04 Checking the Brake Hoses Bleed screw Nm 0.6 m kg, 4.3 ft lb Bleeding the Hydraulic Brake SystemAir bleeding steps Adjusting the Select Lever Control Cable and Shift ROD Adjustment steps Control cableAdjusting the Rear Brake Light Switch Select lever shift rodRecommended oil SAE 80 API GL-4 Hypoid gear oil Direction a Brake light comes on Sooner Direction b LaterChecking the Final Gear OIL Level Changing the Final Gear OIL Checking the Constant Velocity Joint Dust Boots Changing the Differential Gear OILAdjusting the TOE-IN Checking the Steering SystemToe-in = É È Locknut rod end 40 Nm 4.0 m kg, 29 ft lbChecking the Tires Adjusting the Front Shock AbsorbersAdjusting the Rear Shock Absorber Tire Characteristics Manufacturer Size TypeMaxxis Maximum Loading LimitCold tire Front Rear Checking the Wheels Checking and Lubricating the CablesLubricating the LEVERS, PEDAL, ETC Recommended lubricant Lithium soap base greaseChecking the Battery Charging MethodBattery condition checking steps Keep Batteries and Electrolyte OUT of Reach of ChildrenExample Open-circuit Charging timeOr higher No charging is Necessary Charging method using a variable voltage charger YESCharging method using a constant voltage charger Checking the Fuses Quantity Pocket tester YU-03112-CDescription Adjusting the Headlight Beams Changing the Headlight BulbChanging the Headlight Bulb Exhaust pipe AIR DUCTS, Muffler and Exhaust PipeRemoving the air ducts, muffler ENG Coolant reservoir Select Lever Unit and Coolant ReservoirRemoving the select lever unit Hoses and Leads Removing the hoses and leadsInstall all of the bolts/nuts and then SpecificationsEngine Mounting Bolts Tighten Them to full torqueENG Installing the Engine Removing the cylinder head Cylinder Head Removing the Cylinder Head Rotor holding tool YU-01235Checking the Camshaft Sprocket Checking the Tappet CoversChecking the Timing Chain Tensioner ENG Installing the Cylinder Head Installing stepsInstallation steps Cap bolt timing chain tensioner 23 Nm 2.3 m kg, 17 ft lbTighten Camshaft sprocket bolt Removing the camshaft, rocker Arms and valvesCamshaft and Rocker Arms Valves and Valve SpringsENG Removing the Valves and Valve Springs Slide hammer set YU-01083-A Slide hammer bolt M6 WeightRemoving the Camshaft and Rocker Arms Checking the Rocker Arms and Camshaft Valve spring compressor YM-04019Checking the Camshaft Check Rocker arms Rocker arm shafts Damage/wear → Replace Checking the Valves and Valve Springs Runout limit 01 mm 0.0004 U T ION Lapping stepsInstalled length Installing the Valves and Valve Springs Spring tilt limit Inner 1.6 mm 0.06 in OuterInstalling the Camshaft and Rocker Arms Removing the cylinder and piston PistonRemoving the Piston Piston pin puller set YU-01304Do not use a hammer to drive the piston pin out Checking the Timing Chain GuideMeasurement steps 1st step Cylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.327205 mm 00163rd step Checking the Piston RingsSide clearance Standard Limit Top 03 ~ 0.08 mm 13 mm RingEnd gap Standard Limit ~ 0.40 mm 65 mm Ring2nd ~ 0.60 mm 95 mm Ring ~ 0.7 mm RingInstalling the Piston Installing the Cylinder Magneto Removing the A.C. magnetoChapter ENG Starter Disassembling the recoil starterAssembling the Recoil Removing the A.C. Magneto Flywheel puller YM-01404Disassembling the Recoil Starter Checking the A.C. MagnetoChecking the Starter Clutch Bolts starter clutch 30 Nm 3.0 m kg, 22 ft lbAssembling the Recoil Starter Checking the Starter PulleyChecking the Recoil Starter Installing the A.C. Magneto Sealant Quick Gasket ACC-11001-05-01 Yamaha bond NoUse a rotor holding tool 2 to hold the starter pulley Removing the primary Secondary sheavesPrimary and Secondary SheavesFor installation, reverse the removal Primary Sliding Sheave Disassembling the primary slidingSheave SheaveAssembling the Secondary Secondary SheaveDisassembling the secondary Removing the Primary Secondary Sheaves Sheave holder YS-01880-ADisassembling the Secondary Sheave Removing stepsWeight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16 Checking the Primary SheaveChecking the Secondary Sheave Free length 121.4 mm 4.78 Limit 115.33 mm 4.54Assembling the Primary Sheave Assembling the Secondary SheaveNut 90 Nm 9.0 m kg, 65 ft lb Installing the Primary and Secondary Sheaves Removing the clutch ClutchDisassembling the clutch housing Checking the Clutch Removing the ClutchClutch holding tool YM-91042 Installing the Clutch Install Dowel pins Gasket New Clutch housing assembly Starter MOTOR, Timing Chain and OIL Filter Removing the starter motor, timingChain and oil filter OIL Pump Drive GearENG Lever CrankcaseSeparating the crankcase Pump Crankcase BearingsRemoving the crankcase bearings Removing the OIL Pump Drive Gear Removal stepsSeparating the Crankcase Separation stepsChecking the Timing Chain and Guide Checking the OIL Strainer and OIL Delivery PipeAssembling the Crankcase Checking the CrankcaseChecking the Bearings Installing the Shift Lever Installing the OIL Pump Drive Gear Tightening stepsCRANKSHAFT/INSTALLING Removing the crankshaft and oilPump Crankshaft and BalancerOIL Pump Disassembling the oil pumpChecking the OIL Pump Removing the CrankshaftCrankcase separating tool YU-01135-A Checking the Crankshaft Crank width 62.95 ~ 63.00 mm 2.4783 ~ 2.4803Installing the Crankshaft and Balancer Removing the transmission ENG Checking the Shift Forks Do not attempt to straighten a bent guide barChecking the Shift CAM Checking the TransmissionChecking the Secondary Shaft and Driven Sprocket Checking the ChainInstalling the Transmission Drive and Driven Gear Shims Middle Drive ShaftRemoving the middle drive shaft Middle Driven Shaft Removing the middle driven shaftENG Removing the Middle Drive Shaft Removing the Middle Driven ShaftUniversal joint holder YM-04062 Bearing retainer wrench YM-04128Ring nut wrench YM-38404 Checking the Pinion GearsMiddle drive pinion gear shim thickness a = c a b Selecting the Middle Drive and Driven Gear ShimsSelection steps Middle driven pinion gear shim Thickness = d e + f g Hundredths Round value 5, 6Middle drive pinion gear shim Thickness mm ENG Installing the Middle Driven Shaft Tighten the bearing retainer Installing the Middle Drive Shaft Measuring the Middle Gear BacklashMiddle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement steps Pinion gear fix clamp YM-04129Gear lash measurement tool YM-01467 Cool Removing the radiatorCool Checking the Radiator Radiator cap tester YU-24460-01 Adapter YU-33984Installing the Radiator Removing the thermostat Installing the Thermostat Checking the ThermostatRemoving the water pump Disassembling the water pump Disassembling the Water Pump Checking the Water PumpMax. impeller shaft tilt 0.15 mm 0.006 Assembling the Water PumpCool Removing the carburetor Disassembling the carburetor CarburetorCarb Disassembling the Carburetor Checking the CarburetorCarb Float height F.H mm 0.51 Measurement and adjustment steps Assembling the CarburetorAdjusting the Fuel Level Fuel level gauge YM-01312-ADriv Following noises may indicate a mechanical defectTroubleshooting Driv Troubleshooting chart YESRemoving the front constant Velocity joints and differential gearDriv Constant Velocity Joints Disassembling the constant velocityJoints Differential gear Driv Checking the Constant Velocity Joints Removing the Differential Gear AssemblyAlways use new boot bands Assembling the Front Constant Velocity Joints Molybdenum disulfide grease 40 g 1.4 oz per dust bootChecking the Differential Gear Assembling the Differential Gear Gear lash measurement tool YM-01475 Differential gear lash 10 ~ 0.50 mm 0.004 ~ 0.020Adjusting differential gear lash Reduce shimIncrease shim Ring gear shim left and right Thickness mmChecking the Differential Gear Operation Gear assembly and drive shaft InstallingRemoving the rear axle, final drive Rear AxleDisassembling the final drive gear Drive Roller Bearings Assembling the Final DriveGear Removing the Rear Axle Disassembling the Final Drive GearReplacing the Final Drive Roller Bearings Positioning the Final Drive Pinion Gear and Ring Gear Final drive pinion gear shim selectionFinal drive pinion gear shim thickness a = a b Hundredths Rounded value 5, 6Ring gear shim thickness = c + d e + f Bearing thickness f 11.00 mmMeasure/select Ring gear thrust clearance C Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008 Thrust washer selection stepsThrust washer Thickness mm Ring gear stopper shim selectionRing gear stopper clearance adjustment Shim Thickness mmRing gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024 Checking the Rear AxleChecking the Drive Shaft Checking the Final Drive GearFinal gear lash ~ 0.2 mm 0.004 ~ 0.008 Measurement and Adjusting the Final Gear LashFinal gear lash measurement Final gear lash adjustment Ring gear shim Thickness mm 25 0.30 40 0.45 Thrust washerLithium-soap-based grease Installing the Final Drive GearAssembling the Final Drive Gear Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215 Nuts BoltsFront Wheels Removing the front wheelsIs no danger of it falling over HubsRear Wheels Removing the rear wheelsChecking the Wheel Hubs Installing the Wheel Hubs Installing the WheelsChecking the Brake Discs Brake disc maximum deflection 15 mm 0.006Install Nuts wheel Brake Pads Front Brake PadsRemoving the front brake pads Replacing the Front Brake Pads Brake pad wear limit 1 mm 0.04Brake caliper bleed screw 6 Nm 0.6 m kg, 4.3 ft lb Front Brake Master Cylinder Removing the front brake masterCylinder Brake Master CylinderDisassembling the front brake Master cylinderChecking the Master Cylinder Assembling the Front Brake Master CylinderInstalling the Front Brake Master Cylinder Chas Calipers Front Brake CaliperRemoving the front brake calipers Calipers Assembling the Front BrakeChecking the Front Brake Calipers Recommended brake component Replacement schedule Brake padsDisassembling the Front Brake Calipers Installing the Front Brake Calipers Assembling the Front Brake CalipersFill Brake reservoir Removing the rear brake lever Removing the rear brake pedal Removing the rear brake drum Chas Removing the Rear Brake Checking the Rear Brake Installing the Rear Brake Brake shoe lining thickness limit 2.0 mm 0.08Brake drum inside diameter limit maximum 161 mm 6.34 Lithium-soap base greaseBolt camshaft lever Nm 0.9 m kg, 6.5 ft lb Bolt brake shoe plate 28 Nm 2.8 m kg, 20 ft lbChas Cylinder Assembly Brake SwitchHandlebar Removing the handlebarRemoving the Rear Brake Switch Installing the HandlebarInstalling the Rear Brake Lever Checking the HandlebarInstalling the Master Cylinder Assembly Guide Steering StemRemoving the steering stem Bearing Retainer Installing the Bearing Retainer Installing the Cable GuideRemoving the Bearing Retainer Checking the Steering StemTIE Rods and Steering Knuckles Removing the tie rods and steeringKnuckles KnucklesChas Checking the Steering Knuckles Removing the Steering KnucklesChecking the TIE Rods Chas Eye protection is recommended when using striking tools Installing the TIE Rods Removing the front arms and front Shock absorbersArms and Front Shock AbsorberRemoving the Front Arms Checking the Front ArmsReplacement steps Checking the Front Shock Absorber Nut 30 Nm 3.0 m kg, 22 ft lb Installing the Front Arms and Front Shock AbsorberNut 45 Nm 4.5 m kg, 32 ft lb Removing the rear shock absorber SwingarmHousing SwingarmChecking the Rear Shock Absorber Removing the SwingarmNut swingarm 82 Nm 8.2 m kg, 59 ft lb Checking the Swingarm Checking the Rubber BootInstalling the Rubber Boot Installing the Rear Axle Housing Nut 63 Nm 6.3 m kg, 45 ft lb Loctite Bolt Loctite NutElectrical Components Elec Example chart shows that Checking a SwitchChecking a Switch Shown in the Manual Elec + Checking the Switch Continuity Elec Types of Bulbs Checking the Condition of the BulbsPocket tester YU-03112-C Checking the Condition of the Bulb Sockets Circuit Diagram Troubleshooting ProcedureOpen-circuit voltage Or more at 20 C 68 F Standard spark plugSpark plug cap resistance 10 kΩ at 20 C 68 F Spark plug gapMinimum spark gap 6.0 mm 0.24 Both Meet Specification Correct OUT of SpecificationC0NTINUITY Primary coil resistance 18 ~ 0.28 Ω at 20 C 68 FMain switch Refer to Checking the Switches Correct Poor Connection Properly connect the ignition system Replace the CDI unitSystem Electric Starting System Elec If the Starter Motor Fails to Operate Turns Does not TurnIncorrect Correct Starter Motor Removing the starter motorDisassembling the starter motor MotorMica undercut 0.7 mm 0.03 Checking the Starter MotorOutside diameter 28 mm 1.10 Wear limit 27 mm 1.06 Brush length 12.5 mm 0.49 Wear limit 5 mm 0.20 Assembling the Starter MotorCharging If the Battery is not Charged Continuity No ContinuityMeets Specification OUT SpecificationOUT of Specification Charging voltageHeadlight fuse If the Headlight AND/OR Taillight Fail to Come on Correct Incorrect Checking the Lighting System Meets Specification No Continuity Tester + lead → Blue lead 1 Tester lead → Black leadTester + lead → Blue terminal 1 Tester lead → Black terminal Elec Elec Elec EB806010 Properly connect the signal system Checking the Signal System If the neutral indicator light fails to come on If the reverse indicator light fails to come on 235.4 F Test Coolant temperature Thermo switch Continuity StepLess than 120 ± 3 C 248 ± 5.4 F Good Condition BAD ConditionCorrect OUT of Specification Meets Cooling SystemIf the FAN Motor does not Move Meets Specification Does not Turn Circuit breaker resistance Zero Ω at 20 C 68 FGood Less than 86 ± 3 C 186.8 ± 5.4 F176 ± 5.4 F Properly connect the cooling system System If the Gear Motor Fails to Operate Replace the on-command four-wheel drive switch Correct Poor Connection Fuel System Electrical SystemCompression System Poor Medium and HIGH-SPEED PerformanceFaulty Drive Train Hard Shifting Shift Lever does not MoveJumps OUT of Gear Engine Operates but Machine will not MovePoor Braking Effect Poor Speed PerformanceOverheating Malfunction Unstable HandlingHeadlight Dark Bulb Burnt OUTYFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan