Yamaha LIT-11616-16-02, 5TE-F8197-10 service manual Correct Poor Connection

Page 358

2WD/4WD SELECTING SYSTEM

ELEC

–

+

EB803028

6.Wiring connections

●Check the connections of the entire 2WD/ 4WD selecting system.

Refer to “CIRCUIT DIAGRAM”.

CORRECT

POOR CONNECTION

Properly connect the 2WD/4WD selecting system.

Replace the CDI unit.

9 - 51

Image 358

Contents YFM400FAR YFM400FAR Important Information Exploded Diagrams Manual OrganizationGEN Spec Info CHK ENG ADJ Table of Contents Contents Chapter General Information Seat and Side Panels IntroductionFuel Tank Chapter Engine Page Chapter Cooling System Troubleshooting Rear AXLE/FINAL Drive Gear and Drive ShaftChapter Chassis Chapter Electrical Front Arms and Front Shock AbsorbersFaulty Clutch Performance Faulty Drive TrainFaulty Gear Shifting Starting FAILURE/HARD StartingPoor Braking Effect Faulty BrakeOverheating MalfunctionVehicle Identification Number Model LabelReplacement 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 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 panelsRemoving the front carrier, front Front CARRIER, Front Bumper and Front FenderBumper and front fender CHK ADJ Fender Rear Carrier and Rear FenderRemoving the rear carrier and rear 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 Adjusting the Idling Speed Engine idling speed 1,450 ~ 1,550 r/minTurning 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 Speed limiter length adjustment steps Adjusting the Starter CableStarter 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 Recoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib Checking the Ignition TimingEngine speed 1,450 ~ 1,550 r/min LoctiteMeasuring the Compression Pressure Compression gauge YU-33223 Adapter YU-33223-3Measuring 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 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 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 Adjusting the Select Lever Control Cable and Shift ROD Adjustment steps Control cableAdjusting the Rear Brake Light Switch Select lever shift rodChecking 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 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 lbAdjusting the Rear Shock Absorber Adjusting the Front Shock AbsorbersChecking the Tires Maxxis Tire CharacteristicsManufacturer Size Type 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 ChildrenOr higher No charging is Necessary Open-circuit Charging timeExample Charging method using a variable voltage charger YESCharging method using a constant voltage charger Checking the Fuses Description Pocket tester YU-03112-CQuantity Adjusting the Headlight Beams Changing the Headlight BulbChanging 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 Hoses and Leads Removing the hoses and leadsEngine Mounting Bolts Install all of the bolts/nuts and thenSpecifications Tighten Them to full torqueENG Installing the Engine Removing the cylinder head Cylinder Head Removing the Cylinder Head Rotor holding tool YU-01235Checking the Timing Chain Tensioner Checking the Tappet CoversChecking the Camshaft Sprocket 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 Camshaft and Rocker Arms Removing the camshaft, rockerArms and valves 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 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 PistonDo not use a hammer to drive the piston pin out Removing the PistonPiston pin puller set YU-01304 Checking the Timing Chain Guide05 mm Measurement steps 1st stepCylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272 0016Side clearance 3rd stepChecking the Piston Rings Standard Limit Top 03 ~ 0.08 mm 13 mm Ring2nd ~ 0.60 mm 95 mm Ring End gap Standard Limit~ 0.40 mm 65 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 Disassembling the Recoil Starter Removing the A.C. MagnetoFlywheel puller YM-01404 Checking the A.C. MagnetoChecking the Starter Clutch Bolts starter clutch 30 Nm 3.0 m kg, 22 ft lbChecking the Recoil Starter Checking the Starter PulleyAssembling 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 Primary and Secondary Removing the primarySecondary sheaves SheavesFor installation, reverse the removal Sheave Primary Sliding SheaveDisassembling the primary sliding SheaveDisassembling the secondary Secondary SheaveAssembling the Secondary Disassembling the Secondary Sheave Removing the Primary Secondary SheavesSheave holder YS-01880-A Removing stepsChecking the Secondary Sheave Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16Checking the Primary 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 Clutch holding tool YM-91042 Removing the ClutchChecking the Clutch Installing the Clutch Install Dowel pins Gasket New Clutch housing assembly Chain and oil filter Starter MOTOR, Timing Chain and OIL FilterRemoving the starter motor, timing OIL Pump Drive GearENG Separating the crankcase CrankcaseLever Removing the crankcase bearings Crankcase BearingsPump Separating the Crankcase Removing the OIL Pump Drive GearRemoval steps Separation stepsChecking the Timing Chain and Guide Checking the OIL Strainer and OIL Delivery PipeChecking the Bearings Checking the CrankcaseAssembling the Crankcase Installing the Shift Lever Installing the OIL Pump Drive Gear Tightening stepsPump CRANKSHAFT/INSTALLINGRemoving the crankshaft and oil Crankshaft and BalancerOIL Pump Disassembling the oil pumpCrankcase separating tool YU-01135-A Removing the CrankshaftChecking the OIL Pump 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 CAM Checking the Shift ForksDo not attempt to straighten a bent guide bar Checking the TransmissionChecking the Secondary Shaft and Driven Sprocket Checking the ChainInstalling the Transmission Removing the middle drive shaft Middle Drive ShaftDrive and Driven Gear Shims 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 GearsSelection 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 Middle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement steps Installing the Middle Drive ShaftMeasuring the Middle Gear Backlash 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 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 Gear lash measurement tool YM-01475 Differential gear lash 10 ~ 0.50 mm 0.004 ~ 0.020Increase shim Adjusting differential gear lashReduce shim Ring gear shim left and right Thickness mmChecking the Differential Gear Operation Removing the rear axle, final drive Gear assembly and drive shaftInstalling Rear AxleDisassembling the final drive gear Gear Assembling the Final DriveDrive Roller Bearings Removing the Rear Axle Disassembling the Final Drive GearReplacing the Final Drive Roller Bearings Final drive pinion gear shim thickness a = a b Positioning the Final Drive Pinion Gear and Ring GearFinal drive pinion gear shim selection Hundredths Rounded value 5, 6Ring gear shim thickness = c + d e + f Bearing thickness f 11.00 mmMeasure/select Ring gear thrust clearance C Thrust washer Thickness mm Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008Thrust washer selection steps Ring gear stopper shim selectionRing gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024 Ring gear stopper clearance adjustmentShim Thickness mm Checking the Rear AxleChecking the Drive Shaft Checking the Final Drive GearFinal gear lash measurement Measurement and Adjusting the Final Gear LashFinal gear lash ~ 0.2 mm 0.004 ~ 0.008 Final gear lash adjustment Ring gear shim Thickness mm 25 0.30 40 0.45 Thrust washerAssembling the Final Drive Gear Installing the Final Drive GearLithium-soap-based grease Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215 Nuts BoltsIs no danger of it falling over Front WheelsRemoving the front wheels HubsRear Wheels Removing the rear wheelsChecking the Wheel Hubs Checking the Brake Discs Installing the Wheel HubsInstalling the Wheels Brake disc maximum deflection 15 mm 0.006Install Nuts wheel Removing the front brake pads Front Brake PadsBrake 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 Cylinder Front Brake Master CylinderRemoving the front brake master Brake Master CylinderDisassembling the front brake Master cylinderChecking the Master Cylinder Assembling the Front Brake Master CylinderInstalling the Front Brake Master Cylinder Chas Removing the front brake calipers Front Brake CaliperCalipers Calipers Assembling the Front BrakeDisassembling the Front Brake Calipers Recommended brake component Replacement schedule Brake padsChecking 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 Brake drum inside diameter limit maximum 161 mm 6.34 Installing the Rear BrakeBrake shoe lining thickness limit 2.0 mm 0.08 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 Handlebar Cylinder AssemblyBrake Switch Removing the handlebarInstalling the Rear Brake Lever Removing the Rear Brake SwitchInstalling the Handlebar Checking the HandlebarInstalling the Master Cylinder Assembly Removing the steering stem Steering StemGuide Bearing Retainer Removing the Bearing Retainer Installing the Bearing RetainerInstalling the Cable Guide Checking the Steering StemKnuckles 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 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 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 Removing the rear shock absorber SwingarmHousing SwingarmNut 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 Installing the Rear Axle Housing Nut 63 Nm 6.3 m kg, 45 ft lb Loctite Bolt Loctite NutElectrical Components Elec Checking a Switch Shown in the Manual Checking a SwitchExample chart shows that 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 Open-circuit voltage Or more at 20 C 68 F TroubleshootingProcedure Standard spark plugMinimum spark gap 6.0 mm 0.24 Spark plug gapSpark plug cap resistance 10 kΩ at 20 C 68 F C0NTINUITY Both Meet SpecificationCorrect OUT of Specification 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 Disassembling the starter motor Starter MotorRemoving 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 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 ContinuityOUT of Specification Meets SpecificationOUT 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 Less than 120 ± 3 C 248 ± 5.4 F Test Coolant temperature Thermo switch Continuity Step235.4 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 F176 ± 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 Fuel System Electrical SystemCompression System Poor Medium and HIGH-SPEED PerformanceFaulty Drive Train Jumps OUT of Gear Hard ShiftingShift Lever does not Move Engine Operates but Machine will not MoveOverheating Poor Speed PerformancePoor Braking Effect Headlight Dark MalfunctionUnstable Handling Bulb Burnt OUTYFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan