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

Page 355

 

 

 

 

 

 

A

 

 

 

 

 

 

 

B

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

L/B

 

B

 

B

 

L/B

 

W

 

 

 

 

 

 

 

O

 

 

O

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sb

G/W

 

G/W

Sb

 

 

 

 

R/B

L/W

O

B

 

 

 

 

 

 

G/W

 

Br/W

 

Sb

 

R/B

R/B

 

Sb

 

Br/W

 

 

B/W

 

B/W

 

 

R

W/R

W/G

 

 

 

 

G/L

 

Sb B/Y

 

(BLACK)

(BLACK)

 

 

 

 

 

 

(BLACK)

(BLACK)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(BLACK)

(BLACK)

(BLACK)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WIRE HARNESS

SUB-WIRE

WIRE HARNESS

 

SUB-WIRE

 

WIRE HARNESS

SUB-WIRE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HARNESS 1

 

HARNESS 2

 

HARNESS 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

 

R

O

O

C O

O

9

 

 

W/G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W/R

 

 

 

 

 

 

 

 

 

W/R

 

 

 

 

 

 

 

W/G

 

 

 

 

 

 

 

 

 

W/G

B/W

C B/W B/W

0

W/G R

R W/G

 

 

 

 

 

 

 

 

 

 

L/W

 

 

 

 

W/R W/G

W/L W/R

 

 

 

 

 

 

 

 

 

 

R/B

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

W

W

2

R

 

 

 

 

 

 

 

 

 

 

 

 

 

W

W

 

 

 

 

 

 

 

 

 

 

 

 

 

W

W

W

W

 

B

 

 

 

 

 

 

B

G/L

 

 

 

 

W W

W W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

R

R

G/W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

Sb

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

R

 

 

 

 

R

R

5 L/W L/B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

W

W

 

 

 

 

4 B

 

 

B/Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6 L/W

 

 

 

 

 

 

 

(BLACK)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

R

 

 

 

B

B

L/B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

OFF

Br

R

R

Br

B

7

 

 

 

 

 

 

 

 

 

 

 

ON

Br/L

R

R

Br/L

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Br/L

Br

 

 

 

 

 

 

 

 

 

 

 

CIRCUIT DIAGRAM

2WD/4WD SELECTING

 

SYSTEM

2WD/4WD

9 - 48

Br/L

V

Br

Br/L

P

R/Y

Br/L

O

R/W

L/B

N

L/B

W/L

W/L

Br/L

L

 

 

 

Br/R

W

Br/L

Br/R

R/B

R/B

W/L

I

GF

 

 

W Br/R

 

W/L R/W

Br

C

Br

 

B/Y

 

Br

 

Br

QR/Y

R/B

R/WL/B

LY R/Y B G L/B

P

P

Br/R

Br/R

 

 

 

 

 

 

 

J

 

 

 

Br/W Br/R

 

 

Br L/R

 

B Sb

 

 

L/G B

2WD

 

 

 

 

 

 

 

 

4WD

W W/L

R/B

R/B

A

R/B

R/B

DR/B L

Y

 

Br

G/Y

 

Y

B

 

(GRAY)

Y B

B/Y

Br

 

 

B

Y

(GRAY)

XW

Y

Br

B B

Y

Br

B B

(BLACK) (BLACK) (BLACK) (BLACK)

Y

 

Y

R

S

T

Br

Y

L

OFF

OFF

OFF

L/B

G

B

LO

ON

PUSH

 

 

 

HI

 

 

R/B R/W

 

 

 

 

 

 

 

 

(BLACK)

L

Y G

 

B

 

 

 

 

 

 

 

 

 

 

R/W R/B

 

 

 

 

(BLACK)

M

B

L/B

L/B

(BROWN) (BROWN)

Br/W

B L/B

Sb

 

Br/W

L/B W

A

A A

Br/W

L/B W

Sb

 

A

 

Sb W

Br/W L/B

Sb

W/L

(DARK GRAY)

L

 

 

L

 

 

E

 

 

L

B

 

B

Sb

G/W

3 Main switch

4 Battery

 

 

L

 

R/W R/W

[

5 Main fuse

 

 

]!

B L L B

I

Four-wheel drive fuse/ /

 

 

Sb R/W

 

(GRAY) (GRAY)

 

G L R W

 

J

On-command fourR-/Wwheel drive switch

 

Sb

Sb G/L

 

 

 

 

 

K Gear motor

R/W G/L

B

 

 

Y L

Z

B

 

Y

G Y

G

 

U

 

 

U

Y

G

 

Y

G

B

 

 

B

 

G

Y B

B

G

Y

B

 

 

B

 

K

H

 

L/B Br/W Sb

 

 

 

B L

 

B

 

 

 

B

 

B

 

 

 

 

 

 

Sb

 

G/W

A

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

Sb

 

G/W

B A

– + SELECTING SYSTEM ELEC

Image 355
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 ElectricalStarting FAILURE/HARD Starting Faulty Drive TrainFaulty Gear Shifting Faulty Clutch PerformanceMalfunction Faulty BrakeOverheating Poor Braking EffectModel 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 First disconnect the negative lead Rear Carrier and Rear FenderRemoving the rear carrier and rear FenderCHK 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 Loctite Checking the Ignition TimingEngine speed 1,450 ~ 1,550 r/min Recoil starter bolt 10 Nm 1.0 m kg, 7.2 ft IbCompression 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 Maximum Loading Limit Tire CharacteristicsManufacturer Size Type MaxxisCold 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 LeadsTighten Them to full torque Install all of the bolts/nuts and thenSpecifications Engine Mounting BoltsENG 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 Valves and Valve Springs Removing the camshaft, rockerArms and valves Camshaft and Rocker ArmsENG 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 pistonChecking the Timing Chain Guide Removing the PistonPiston pin puller set YU-01304 Do not use a hammer to drive the piston pin out0016 Measurement steps 1st stepCylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272 05 mmStandard Limit Top 03 ~ 0.08 mm 13 mm Ring 3rd stepChecking the Piston Rings Side clearance~ 0.7 mm Ring End gap Standard Limit~ 0.40 mm 65 mm Ring 2nd ~ 0.60 mm 95 mm RingInstalling the Piston Installing the Cylinder Chapter Removing the A.C. magnetoMagneto ENG Assembling the Recoil Disassembling the recoil starterStarter Checking the A.C. Magneto Removing the A.C. MagnetoFlywheel puller YM-01404 Disassembling the Recoil StarterBolts 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 Sheaves Removing the primarySecondary sheaves Primary and SecondaryFor installation, reverse the removal Sheave Primary Sliding SheaveDisassembling the primary sliding SheaveDisassembling the secondary Secondary SheaveAssembling the Secondary Removing steps Removing the Primary Secondary SheavesSheave holder YS-01880-A Disassembling the Secondary SheaveFree length 121.4 mm 4.78 Limit 115.33 mm 4.54 Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16Checking the Primary Sheave Checking the Secondary SheaveAssembling 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 OIL Pump Drive Gear Starter MOTOR, Timing Chain and OIL FilterRemoving the starter motor, timing Chain and oil filterENG Separating the crankcase CrankcaseLever Removing the crankcase bearings Crankcase BearingsPump Separation steps Removing the OIL Pump Drive GearRemoval steps Separating the CrankcaseChecking 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 GearCrankshaft and Balancer CRANKSHAFT/INSTALLINGRemoving the crankshaft and oil PumpDisassembling 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 Checking the Transmission Checking the Shift ForksDo not attempt to straighten a bent guide bar Checking the Shift CAMChecking 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 Pinion gear fix clamp YM-04129 Installing the Middle Drive ShaftMeasuring the Middle Gear Backlash Middle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement stepsGear 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-01475Ring gear shim left and right Thickness mm Adjusting differential gear lashReduce shim Increase shimChecking the Differential Gear Operation Rear Axle Gear assembly and drive shaftInstalling Removing the rear axle, final driveDisassembling 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 Hundredths Rounded value 5, 6 Positioning the Final Drive Pinion Gear and Ring GearFinal drive pinion gear shim selection Final drive pinion gear shim thickness a = a bBearing thickness f 11.00 mm Ring gear shim thickness = c + d e + fMeasure/select Ring gear thrust clearance C Ring gear stopper shim selection Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008Thrust washer selection steps Thrust washer Thickness mmChecking the Rear Axle Ring gear stopper clearance adjustmentShim Thickness mm Ring gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024Checking 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.1215Hubs Front WheelsRemoving the front wheels Is no danger of it falling overRemoving the rear wheels Rear WheelsChecking the Wheel Hubs Brake disc maximum deflection 15 mm 0.006 Installing the Wheel HubsInstalling the Wheels Checking the Brake DiscsInstall 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 Brake Master Cylinder Front Brake Master CylinderRemoving the front 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 Lithium-soap base grease Installing the Rear BrakeBrake shoe lining thickness limit 2.0 mm 0.08 Brake drum inside diameter limit maximum 161 mm 6.34Bolt brake shoe plate 28 Nm 2.8 m kg, 20 ft lb Bolt camshaft lever Nm 0.9 m kg, 6.5 ft lbChas Removing the handlebar Cylinder AssemblyBrake Switch HandlebarChecking the Handlebar Removing the Rear Brake SwitchInstalling the Handlebar Installing the Rear Brake LeverInstalling the Master Cylinder Assembly Removing the steering stem Steering StemGuide Bearing Retainer Checking the Steering Stem Installing the Bearing RetainerInstalling the Cable Guide Removing the Bearing RetainerKnuckles TIE Rods and Steering KnucklesRemoving the tie rods and steering 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 Standard spark plug TroubleshootingProcedure Open-circuit voltage Or more at 20 C 68 FMinimum spark gap 6.0 mm 0.24 Spark plug gapSpark plug cap resistance 10 kΩ at 20 C 68 F Primary coil resistance 18 ~ 0.28 Ω at 20 C 68 F Both Meet SpecificationCorrect OUT of Specification C0NTINUITYMain 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 Motor Starter MotorRemoving the starter motor Disassembling the starter 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 ChargedCharging voltage Meets SpecificationOUT Specification OUT of SpecificationHeadlight 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 Engine Operates but Machine will not Move Hard ShiftingShift Lever does not Move Jumps OUT of GearOverheating Poor Speed PerformancePoor Braking Effect Bulb Burnt OUT MalfunctionUnstable Handling Headlight DarkYFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan