Yamaha 5TE-F8197-10, LIT-11616-16-02 service manual If the reverse indicator light fails to come on

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SIGNAL SYSTEM

3.If the reverse indicator light fails to come on:

ELEC –

+

1.Bulb and bulb socket

●Check the bulb and bulb socket for continuity.

CONTINUITY

2.Reverse switch

Refer to “CHECKING THE SWITCHES”.

NO CONTINUITY

Replace the bulb and/or bulb socket.

NO CONTINUITY

CONTINUITY

Replace the reverse switch.

3.Voltage

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

Tester (+) lead → Red/White terminal 1 Tester (–) lead → Green/Blue terminal 2

●Turn the main switch to “ON”.

●Check the voltage (12 V).

MEETS

SPECIFICATION

Replace the CDI unit.

OUT OF SPECIFICATION

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

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Contents YFM400FAR YFM400FAR Important Information Manual Organization Exploded DiagramsGEN Spec Info CHK ENG ADJ Table of Contents Contents Chapter General Information Introduction Seat and Side PanelsFuel 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 NumberPreparation for Removal Procedures Replacement PartsGASKETS, OIL Seals and O-RINGS Lock WASHERS/PLATES and Cotter Pins Bearings and OIL SealsCirclips Checking of Connections Tool No Tool name/How to use Illustration Crankshaft installer set Sheave fixed block Compression gauge Clutch holding tool General Specifications Mikuni DR8EA/NGKMaxxis 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 MS5F-561/JIDECO 4BA/DENSO5ND/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 PanelsFront CARRIER, Front Bumper and Front Fender Removing the front carrier, frontBumper and front fender CHK ADJ Removing the rear carrier and rear Rear Carrier and Rear FenderFender First disconnect the negative leadCHK ADJ Fuel Tank Removing the fuel tankBumper and Front Fender Removing the footrest boards Adjusting the Valve Clearance Adjusting the Valve Clearance Adjustment steps Tappet adjusting tool YM-08035Locknut 20 Nm 2.0 m kg, 14 ft lb Engine idling speed 1,450 ~ 1,550 r/min Adjusting the Idling SpeedAdjusting the Throttle Lever Free Play Turning Idling speed becomes Higher Turning out LowerThrottle lever free play ~ 5 mm 0.12 ~ 0.20 Adjustment steps First step Adjusting the Speed Limiter Second stepSpeed limiter length 12 mm 0.47 Adjusting the Starter Cable Speed limiter length adjustment stepsStarter plunger stroke distance 15 mm 0.59 Checking the Spark Plug Standard spark plug DR8EA/NGKSpark 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 Recommended oil Follow the left chart Checking the Engine OIL LevelDo not allow foreign material to enter the crankcase Replacement steps Changing the Engine OILOil 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 Coolant Temperature Checking the V-BELTBelt width 30.7 mm 1.21 in Limit 27.6 mm 1.09 Replacing steps Cleaning the Spark Arrester Adjusting the Rear Brake Rear brake pedal free play 20 ~ 30 mm 0.80 ~ 1.18Rear brake pedal free play 20 ~ 30 mm 0.8 ~ 1.2 Gap a ~ 1 mm 0.00 ~ 0.04 Checking the Front Brake Fluid Level Recommended brake fluidDOT Checking the Front Brake Pads Brake pad wear limit a 1 mm 0.04Checking the Rear Brake Shoes Checking the Brake Hoses Bleeding the Hydraulic Brake System Air bleeding stepsBleed 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 SwitchDirection a Brake light comes on Sooner Direction b Later Checking the Final Gear OIL LevelRecommended 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 Front Shock Absorbers Adjusting the Rear Shock AbsorberChecking 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 stepsOpen-circuit Charging time Or higher No charging is NecessaryExample YES Charging method using a variable voltage chargerCharging method using a constant voltage charger Checking the Fuses Pocket tester YU-03112-C DescriptionQuantity Changing the Headlight Bulb Adjusting the Headlight BeamsChanging the Headlight Bulb AIR DUCTS, Muffler and Exhaust Pipe Removing the air ducts, mufflerExhaust pipe ENG Select Lever Unit and Coolant Reservoir Removing the select lever unitCoolant 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 Tappet Covers Checking the Timing Chain TensionerChecking 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 Slide hammer set YU-01083-A Slide hammer bolt M6 Weight Removing the Camshaft and Rocker ArmsRemoving the Valves and Valve Springs Valve spring compressor YM-04019 Checking the CamshaftChecking 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 Removing the A.C. magneto ChapterMagneto ENG Disassembling the recoil starter Assembling the RecoilStarter 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 Starter Pulley Checking the Recoil StarterAssembling 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 SheaveSecondary Sheave Disassembling the secondaryAssembling 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 Removing the Clutch Clutch holding tool YM-91042Checking 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 Crankcase Separating the crankcaseLever Crankcase Bearings Removing the 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 Crankcase Checking the BearingsAssembling 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 PumpRemoving the Crankshaft Crankcase separating tool YU-01135-AChecking 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 Middle Drive Shaft Removing the 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-38404Selecting the Middle Drive and Driven Gear Shims Selection stepsMiddle drive pinion gear shim thickness a = c a b Hundredths Round value 5, 6 Middle drive pinion gear shim Thickness mmMiddle 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 Disassembling the constant velocity JointsConstant Velocity Joints Differential gear Driv Removing the Differential Gear Assembly Always use new boot bandsChecking the Constant Velocity Joints Molybdenum disulfide grease 40 g 1.4 oz per dust boot Checking the Differential GearAssembling 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 Assembling the Final Drive GearDrive 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 ShaftMeasurement and Adjusting the Final Gear Lash Final gear lash measurementFinal 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 adjustmentInstalling the Final Drive Gear Assembling 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 Front Brake Pads Removing the 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 Front Brake Caliper Removing the front brake calipersCalipers Assembling the Front Brake CalipersRecommended brake component Replacement schedule Brake pads Disassembling the Front Brake CalipersChecking 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 Steering Stem Removing the 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 Removing the Steering Knuckles Checking the TIE RodsChecking 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 Installing the Front Arms and Front Shock Absorber Nut 45 Nm 4.5 m kg, 32 ft lbNut 30 Nm 3.0 m kg, 22 ft lb Swingarm Removing the rear shock absorberSwingarm HousingRemoving the Swingarm Nut swingarm 82 Nm 8.2 m kg, 59 ft lbChecking the Rear Shock Absorber Checking the Rubber Boot Installing 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 Checking a Switch Shown in the ManualExample 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 plugSpark plug gap Minimum spark gap 6.0 mm 0.24Spark 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 MotorChecking the Starter Motor Outside diameter 28 mm 1.10 Wear limit 27 mm 1.06Mica 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 Test Coolant temperature Thermo switch Continuity Step Less than 120 ± 3 C 248 ± 5.4 F235.4 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 TurnLess than 86 ± 3 C 186.8 ± 5.4 F 176 ± 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 MovePoor Speed Performance OverheatingPoor Braking Effect Unstable Handling MalfunctionHeadlight Dark Bulb Burnt OUTYFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan