Yamaha 5TE-F8197-10, LIT-11616-16-02 Tester + lead → Blue terminal 1 Tester lead → Black terminal

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LIGHTING SYSTEM

ELEC

–

+

EB805021

3.If the speedometer light fails to come on:

1.Bulb and bulb socket

●Check the bulb and bulb socket for continuity.

CONTINUITY

2.Voltage

●Connect the pocket tester (20 V) to the bulb socket coupler.

Tester (+) lead → Blue terminal 1 Tester (–) lead → Black terminal 2

●Turn the main switch to “ON”.

●Turn the light switch to “ ” or “ ”.

●Check the voltage (12 V).

MEETS

SPECIFICATION

This circuit is not faulty.

NO CONTINUITY

Replace the bulb and/or bulb socket.

OUT OF SPECIFICATION

The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.

9 - 30

Image 337

Contents YFM400FAR YFM400FAR Important Information Manual Organization Exploded DiagramsGEN Spec Info CHK ENG ADJ Table of Contents Contents Chapter General Information Seat and Side Panels IntroductionFuel Tank Chapter Engine Page Chapter Cooling System Rear AXLE/FINAL Drive Gear and Drive Shaft TroubleshootingChapter Chassis Front Arms and Front Shock Absorbers Chapter ElectricalFaulty Gear Shifting Faulty Drive TrainFaulty Clutch Performance Starting FAILURE/HARD StartingOverheating Faulty BrakePoor Braking Effect MalfunctionModel Label Vehicle Identification NumberReplacement Parts Preparation for Removal ProceduresGASKETS, OIL Seals and O-RINGS Bearings and OIL Seals Lock WASHERS/PLATES and Cotter PinsCirclips Checking of Connections Tool No Tool name/How to use Illustration Crankshaft installer set Sheave fixed block Compression gauge Clutch holding tool General Specifications DR8EA/NGK MikuniMaxxis 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 4BA/DENSO MS5F-561/JIDECO5ND/NIPPON Thermostat Conversion Table Metric Multiplier ImperialLubrication 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 Removing the seat and side panels Seat and Side PanelsRemoving the front carrier, front Front CARRIER, Front Bumper and Front FenderBumper and front fender CHK ADJ Removing the rear carrier and rear Rear Carrier and Rear FenderFender First disconnect the negative leadCHK ADJ Removing the fuel tank Fuel TankBumper and Front Fender Removing the footrest boards Adjusting the Valve Clearance Adjusting the Valve Clearance Tappet adjusting tool YM-08035 Adjustment stepsLocknut 20 Nm 2.0 m kg, 14 ft lb Engine idling speed 1,450 ~ 1,550 r/min Adjusting the Idling SpeedTurning Idling speed becomes Higher Turning out Lower Adjusting the Throttle Lever Free PlayThrottle lever free play ~ 5 mm 0.12 ~ 0.20 Adjustment steps First step Second step Adjusting the Speed LimiterSpeed limiter length 12 mm 0.47 Adjusting the Starter Cable Speed limiter length adjustment stepsStarter plunger stroke distance 15 mm 0.59 Standard spark plug DR8EA/NGK Checking the Spark PlugSpark plug gap ~ 0.7 mm 0.024 ~ 0.028 Engine speed 1,450 ~ 1,550 r/min Checking the Ignition TimingRecoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib LoctiteCompression gauge YU-33223 Adapter YU-33223-3 Measuring the Compression PressureMeasuring the Compression Pressure Checking the Engine OIL Level Recommended oil Follow the left chartDo not allow foreign material to enter the crankcase Changing the Engine OIL Replacement stepsOil filter wrench YU-38411 Oil filter cartridge 17 Nm 1.7 m kg, 12 ft lb Cautio NOil gallery bolt Nm 0.7 m kg, 5.1 ft lb Cleaning the AIR FilterCleaning the AIR Filter Cleaning steps Checking the Coolant Level Changing the Coolant 10 Nm 1.0 m kg, 7.2 ft lb CHK ADJ Checking the V-BELT Checking the Coolant TemperatureBelt width 30.7 mm 1.21 in Limit 27.6 mm 1.09 Replacing steps Cleaning the Spark Arrester Rear brake pedal free play 20 ~ 30 mm 0.80 ~ 1.18 Adjusting the Rear BrakeRear brake pedal free play 20 ~ 30 mm 0.8 ~ 1.2 Gap a ~ 1 mm 0.00 ~ 0.04 Recommended brake fluid Checking the Front Brake Fluid LevelDOT Brake pad wear limit a 1 mm 0.04 Checking the Front Brake PadsChecking the Rear Brake Shoes Checking the Brake Hoses Air bleeding steps Bleeding the Hydraulic Brake SystemBleed screw Nm 0.6 m kg, 4.3 ft lb Adjustment steps Control cable Adjusting the Select Lever Control Cable and Shift RODSelect lever shift rod Adjusting the Rear Brake Light SwitchChecking the Final Gear OIL Level Direction a Brake light comes on Sooner Direction b LaterRecommended oil SAE 80 API GL-4 Hypoid gear oil Changing the Final Gear OIL Changing the Differential Gear OIL Checking the Constant Velocity Joint Dust BootsChecking the Steering System Adjusting the TOE-INLocknut rod end 40 Nm 4.0 m kg, 29 ft lb Toe-in = É ÈAdjusting the Rear Shock Absorber Adjusting the Front Shock AbsorbersChecking the Tires Manufacturer Size Type Tire CharacteristicsMaxxis Maximum Loading LimitCold tire Front Rear Checking and Lubricating the Cables Checking the WheelsRecommended lubricant Lithium soap base grease Lubricating the LEVERS, PEDAL, ETCCharging Method Checking the BatteryKeep Batteries and Electrolyte OUT of Reach of Children Battery condition checking stepsOr higher No charging is Necessary Open-circuit Charging timeExample YES Charging method using a variable voltage chargerCharging method using a constant voltage charger Checking the Fuses Description Pocket tester YU-03112-CQuantity Changing the Headlight Bulb Adjusting the Headlight BeamsChanging the Headlight Bulb Removing the air ducts, muffler AIR DUCTS, Muffler and Exhaust PipeExhaust pipe ENG Removing the select lever unit Select Lever Unit and Coolant ReservoirCoolant reservoir Removing the hoses and leads Hoses and LeadsSpecifications Install all of the bolts/nuts and thenEngine Mounting Bolts Tighten Them to full torqueENG Installing the Engine Removing the cylinder head Cylinder Head Rotor holding tool YU-01235 Removing the Cylinder HeadChecking the Timing Chain Tensioner Checking the Tappet CoversChecking the Camshaft Sprocket ENG Installing steps Installing the Cylinder HeadCap bolt timing chain tensioner 23 Nm 2.3 m kg, 17 ft lb Installation stepsTighten Camshaft sprocket bolt Arms and valves Removing the camshaft, rockerCamshaft and Rocker Arms Valves and Valve SpringsENG Removing the Camshaft and Rocker Arms Slide hammer set YU-01083-A Slide hammer bolt M6 WeightRemoving the Valves and Valve Springs Checking the Camshaft Valve spring compressor YM-04019Checking the Rocker Arms and Camshaft Check Rocker arms Rocker arm shafts Damage/wear → Replace Checking the Valves and Valve Springs Runout limit 01 mm 0.0004 Lapping steps U T IONInstalled length Spring tilt limit Inner 1.6 mm 0.06 in Outer Installing the Valves and Valve SpringsInstalling the Camshaft and Rocker Arms Piston Removing the cylinder and pistonPiston pin puller set YU-01304 Removing the PistonDo not use a hammer to drive the piston pin out Checking the Timing Chain GuideCylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272 Measurement steps 1st step05 mm 0016Checking the Piston Rings 3rd stepSide clearance Standard Limit Top 03 ~ 0.08 mm 13 mm Ring~ 0.40 mm 65 mm Ring End gap Standard Limit2nd ~ 0.60 mm 95 mm Ring ~ 0.7 mm RingInstalling the Piston Installing the Cylinder Chapter Removing the A.C. magnetoMagneto ENG Assembling the Recoil Disassembling the recoil starterStarter Flywheel puller YM-01404 Removing the A.C. MagnetoDisassembling the Recoil Starter Checking the A.C. MagnetoBolts starter clutch 30 Nm 3.0 m kg, 22 ft lb Checking the Starter ClutchChecking the Recoil Starter Checking the Starter PulleyAssembling the Recoil Starter Sealant Quick Gasket ACC-11001-05-01 Yamaha bond No Installing the A.C. MagnetoUse a rotor holding tool 2 to hold the starter pulley Secondary sheaves Removing the primaryPrimary and Secondary SheavesFor installation, reverse the removal Disassembling the primary sliding Primary Sliding SheaveSheave SheaveDisassembling the secondary Secondary SheaveAssembling the Secondary Sheave holder YS-01880-A Removing the Primary Secondary SheavesDisassembling the Secondary Sheave Removing stepsChecking the Primary Sheave Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16Checking the Secondary Sheave Free length 121.4 mm 4.78 Limit 115.33 mm 4.54Assembling the Secondary Sheave Assembling the Primary SheaveNut 90 Nm 9.0 m kg, 65 ft lb Installing the Primary and Secondary Sheaves Clutch Removing the clutchDisassembling the clutch housing Clutch holding tool YM-91042 Removing the ClutchChecking the Clutch Installing the Clutch Install Dowel pins Gasket New Clutch housing assembly Removing the starter motor, timing Starter MOTOR, Timing Chain and OIL FilterChain and oil filter OIL Pump Drive GearENG Separating the crankcase CrankcaseLever Removing the crankcase bearings Crankcase BearingsPump Removal steps Removing the OIL Pump Drive GearSeparating the Crankcase Separation stepsChecking the OIL Strainer and OIL Delivery Pipe Checking the Timing Chain and GuideChecking the Bearings Checking the CrankcaseAssembling the Crankcase Installing the Shift Lever Tightening steps Installing the OIL Pump Drive GearRemoving the crankshaft and oil CRANKSHAFT/INSTALLINGPump Crankshaft and BalancerDisassembling the oil pump OIL PumpCrankcase separating tool YU-01135-A Removing the CrankshaftChecking the OIL Pump Crank width 62.95 ~ 63.00 mm 2.4783 ~ 2.4803 Checking the CrankshaftInstalling the Crankshaft and Balancer Removing the transmission ENG Do not attempt to straighten a bent guide bar Checking the Shift ForksChecking the Shift CAM Checking the TransmissionChecking the Chain Checking the Secondary Shaft and Driven SprocketInstalling the Transmission Removing the middle drive shaft Middle Drive ShaftDrive and Driven Gear Shims Removing the middle driven shaft Middle Driven ShaftENG Removing the Middle Driven Shaft Removing the Middle Drive ShaftBearing retainer wrench YM-04128 Universal joint holder YM-04062Checking the Pinion Gears Ring nut wrench YM-38404Selection steps Selecting the Middle Drive and Driven Gear ShimsMiddle drive pinion gear shim thickness a = c a b Middle drive pinion gear shim Thickness mm Hundredths Round value 5, 6Middle driven pinion gear shim Thickness = d e + f g ENG Installing the Middle Driven Shaft Tighten the bearing retainer Measuring the Middle Gear Backlash Installing the Middle Drive ShaftMiddle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement steps Pinion gear fix clamp YM-04129Gear lash measurement tool YM-01467 Removing the radiator CoolCool Radiator cap tester YU-24460-01 Adapter YU-33984 Checking the RadiatorInstalling the Radiator Removing the thermostat Checking the Thermostat Installing the ThermostatRemoving the water pump Disassembling the water pump Checking the Water Pump Disassembling the Water PumpAssembling the Water Pump Max. impeller shaft tilt 0.15 mm 0.006Cool Removing the carburetor Carburetor Disassembling the carburetorCarb Checking the Carburetor Disassembling the CarburetorCarb Assembling the Carburetor Float height F.H mm 0.51 Measurement and adjustment stepsFuel level gauge YM-01312-A Adjusting the Fuel LevelFollowing noises may indicate a mechanical defect DrivTroubleshooting Driv YES Troubleshooting chartVelocity joints and differential gear Removing the front constantDriv Joints Disassembling the constant velocityConstant Velocity Joints Differential gear Driv Always use new boot bands Removing the Differential Gear AssemblyChecking the Constant Velocity Joints Checking the Differential Gear Molybdenum disulfide grease 40 g 1.4 oz per dust bootAssembling the Front Constant Velocity Joints Assembling the Differential Gear Differential gear lash 10 ~ 0.50 mm 0.004 ~ 0.020 Gear lash measurement tool YM-01475Reduce shim Adjusting differential gear lashIncrease shim Ring gear shim left and right Thickness mmChecking the Differential Gear Operation Installing Gear assembly and drive shaftRemoving the rear axle, final drive Rear AxleDisassembling the final drive gear Gear Assembling the Final DriveDrive Roller Bearings Disassembling the Final Drive Gear Removing the Rear AxleReplacing the Final Drive Roller Bearings Final drive pinion gear shim selection Positioning the Final Drive Pinion Gear and Ring GearFinal drive pinion gear shim thickness a = a b Hundredths Rounded value 5, 6Bearing thickness f 11.00 mm Ring gear shim thickness = c + d e + fMeasure/select Ring gear thrust clearance C Thrust washer selection steps Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008Thrust washer Thickness mm Ring gear stopper shim selectionShim Thickness mm Ring gear stopper clearance adjustmentRing gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024 Checking the Rear AxleChecking the Final Drive Gear Checking the Drive ShaftFinal gear lash measurement Measurement and Adjusting the Final Gear LashFinal gear lash ~ 0.2 mm 0.004 ~ 0.008 Ring gear shim Thickness mm 25 0.30 40 0.45 Thrust washer Final gear lash adjustmentAssembling the Final Drive Gear Installing the Final Drive GearLithium-soap-based grease Nuts Bolts Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215Removing the front wheels Front WheelsIs no danger of it falling over HubsRemoving the rear wheels Rear WheelsChecking the Wheel Hubs Installing the Wheels Installing the Wheel HubsChecking the Brake Discs Brake disc maximum deflection 15 mm 0.006Install Nuts wheel Removing the front brake pads Front Brake PadsBrake Pads Brake pad wear limit 1 mm 0.04 Replacing the Front Brake PadsBrake caliper bleed screw 6 Nm 0.6 m kg, 4.3 ft lb Removing the front brake master Front Brake Master CylinderCylinder Brake Master CylinderMaster cylinder Disassembling the front brakeAssembling the Front Brake Master Cylinder Checking the Master CylinderInstalling the Front Brake Master Cylinder Chas Removing the front brake calipers Front Brake CaliperCalipers Assembling the Front Brake CalipersDisassembling the Front Brake Calipers Recommended brake component Replacement schedule Brake padsChecking the Front Brake Calipers Assembling the Front Brake Calipers Installing 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 Brake shoe lining thickness limit 2.0 mm 0.08 Installing the Rear BrakeBrake drum inside diameter limit maximum 161 mm 6.34 Lithium-soap base greaseBolt brake shoe plate 28 Nm 2.8 m kg, 20 ft lb Bolt camshaft lever Nm 0.9 m kg, 6.5 ft lbChas Brake Switch Cylinder AssemblyHandlebar Removing the handlebarInstalling the Handlebar Removing the Rear Brake SwitchInstalling the Rear Brake Lever Checking the HandlebarInstalling the Master Cylinder Assembly Removing the steering stem Steering StemGuide Bearing Retainer Installing the Cable Guide Installing the Bearing RetainerRemoving the Bearing Retainer Checking the Steering StemRemoving the tie rods and steering TIE Rods and Steering KnucklesKnuckles KnucklesChas Checking the TIE Rods Removing the Steering KnucklesChecking the Steering Knuckles Chas Eye protection is recommended when using striking tools Installing the TIE Rods Shock absorbers Removing the front arms and frontAbsorber Arms and Front ShockChecking the Front Arms Removing the Front ArmsReplacement steps Checking the Front Shock Absorber Nut 45 Nm 4.5 m kg, 32 ft lb Installing the Front Arms and Front Shock AbsorberNut 30 Nm 3.0 m kg, 22 ft lb Swingarm Removing the rear shock absorberSwingarm HousingNut swingarm 82 Nm 8.2 m kg, 59 ft lb Removing the SwingarmChecking the Rear Shock Absorber Installing the Rubber Boot Checking the Rubber BootChecking the Swingarm Nut 63 Nm 6.3 m kg, 45 ft lb Loctite Bolt Loctite Nut Installing the Rear Axle HousingElectrical Components Elec Checking a Switch Shown in the Manual Checking a SwitchExample chart shows that Elec + Checking the Switch Continuity Elec Checking the Condition of the Bulbs Types of BulbsPocket tester YU-03112-C Checking the Condition of the Bulb Sockets Circuit Diagram Procedure TroubleshootingOpen-circuit voltage Or more at 20 C 68 F Standard spark plugMinimum spark gap 6.0 mm 0.24 Spark plug gapSpark plug cap resistance 10 kΩ at 20 C 68 F Correct OUT of Specification Both Meet SpecificationC0NTINUITY Primary coil resistance 18 ~ 0.28 Ω at 20 C 68 FMain switch Refer to Checking the Switches Properly connect the ignition system Replace the CDI unit Correct Poor ConnectionSystem Electric Starting System Elec If the Starter Motor Fails to Operate Does not Turn TurnsIncorrect Correct Removing the starter motor Starter MotorDisassembling the starter motor MotorOutside diameter 28 mm 1.10 Wear limit 27 mm 1.06 Checking the Starter MotorMica undercut 0.7 mm 0.03 Assembling the Starter Motor Brush length 12.5 mm 0.49 Wear limit 5 mm 0.20Charging Continuity No Continuity If the Battery is not ChargedOUT Specification Meets SpecificationOUT of Specification Charging voltageHeadlight fuse If the Headlight AND/OR Taillight Fail to Come on Correct Incorrect Checking the Lighting System Tester + lead → Blue lead 1 Tester lead → Black lead Meets Specification No ContinuityTester + 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 Less than 120 ± 3 C 248 ± 5.4 F Test Coolant temperature Thermo switch Continuity Step235.4 F BAD Condition Good ConditionCorrect OUT of Specification Meets System CoolingIf the FAN Motor does not Move Circuit breaker resistance Zero Ω at 20 C 68 F Meets Specification Does not Turn176 ± 5.4 F Less than 86 ± 3 C 186.8 ± 5.4 FGood Properly connect the cooling system System If the Gear Motor Fails to Operate Replace the on-command four-wheel drive switch Correct Poor Connection Electrical System Fuel SystemPoor Medium and HIGH-SPEED Performance Compression SystemFaulty Drive Train Shift Lever does not Move Hard ShiftingJumps OUT of Gear Engine Operates but Machine will not MoveOverheating Poor Speed PerformancePoor Braking Effect Unstable Handling MalfunctionHeadlight Dark Bulb Burnt OUTYFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan