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5TE-F8197-10, LIT-11616-16-02 service manual
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LIT-11616-16-02 5TE-F8197-10
YFM400FAR
SERVICE MANUAL
Contents
Main
Page
NOTICE
HOW TO USE THIS MANUAL
ILLUSTRATED SYMBOLS
Illustrated symbols A to H are used to identify the specifications appearing in the text.
INFO SPEC
ADJ ENG COOL CARB
ELEC TRBL
EGM
TABLE OF CONTENTS
Page
CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS
CHAPTER 4. ENGINE
Page
CHAPTER 5. COOLING SYSTEM
CHAPTER 6. CARBURETION
CHAPTER 7. DRIVE TRAIN
CHAPTER 8. CHASSIS
CHAPTER 9. ELECTRICAL
CHAPTER 10. TROUBLESHOOTING
Page
Page
1 - 2
1 - 3
1 - 4
CHECKING OF CONNECTIONS
1 - 5
1 - 6
1 - 7
1 - 8
1 - 9
2 - 1
SPECIFICATIONS
2 - 2
2 - 3
2 - 4
2 - 5
*
2 - 6
2 - 7
*
2 - 8
2 - 9
2 - 10
Page
2 - 12
2 - 13
2 - 14
2 - 15
2 - 16
2 - 17
2 - 18
2 - 19
2 - 20
HOW TO USE THE CONVERSION TABLE
GENERAL TORQUE SPECIFICATIONS
HOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS
2 - 21
LUBRICATION POINTS AND LUBRICANT TYPES
Page
Page
Page
Page
Page
Page
Page
Page
2 - 30
CABLE ROUTING
2 - 31
CABLE ROUTING
Page
Page
Page
Page
Page
3 - 1
INTRODUCTION/
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
3 - 2
Page
3 - 4
Page
3 - 6
Page
3 - 8
Page
3 - 10
ENGINE
3 - 11
3 - 12
3 - 13
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE IDLING SPEED
3 - 14
ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY
3 - 15
ADJUSTING THE THROTTLE LEVER FREE PLAY
3 - 16
ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER
3 - 17
ADJUSTING THE SPEED LIMITER/ ADJUSTING THE STARTER CABLE
3 - 18
ADJUSTING THE STARTER CABLE
3 - 19
CHECKING THE SPARK PLUG
3 - 20
CHECKING THE IGNITION TIMING
3 - 21
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE
3 - 22
MEASURING THE COMPRESSION PRESSURE
3 - 23
CHECKING THE ENGINE OIL LEVEL
3 - 24
CHANGING THE ENGINE OIL
3 - 25
CHANGING THE ENGINE OIL
3 - 26
CHANGING THE ENGINE OIL/
3 - 27
3 - 28
3 - 29
CHECKING THE COOLANT LEVEL
3 - 30
3 - 31
3 - 32
3 - 33
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT/CHECKING THE V-BELT
3 - 34
CHECKING THE V-BELT
3 - 35
CLEANING THE SPARK ARRESTER
3 - 36
ADJUSTING THE REAR BRAKE CHASSIS
3 - 37
ADJUSTING THE REAR BRAKE
3 - 38
CHECKING THE FRONT BRAKE FLUID LEVEL
3 - 39
CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE SHOES
3 - 40
CHECKING THE BRAKE HOSES
3 - 41
BLEEDING THE HYDRAULIC BRAKE SYSTEM
3 - 42
3 - 43
3 - 44
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL
***********************************************
3 - 45
CHANGING THE FINAL GEAR OIL
3 - 46
CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS
3 - 47
CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN
3 - 48
ADJUSTING THE TOE-IN
3 - 49
3 - 50
CHECKING THE TIRES
3 - 51
CHECKING THE TIRES
3 - 52
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES
Page
3 - 54
ELECTRICAL
3 - 55
3 - 56
3 - 57
Charging method using a variable voltage charger
3 - 58
Charging method using a constant voltage charger
3 - 59
CHECKING THE BATTERY/ CHECKING THE FUSES
3 - 60
CHECKING THE FUSES
3 - 61
CHECKING THE FUSES/ADJUSTING THE HEADLIGHT BEAMS/CHANGING THE HEADLIGHT BULB
3 - 62
CHANGING THE HEADLIGHT BULB
4 - 1
ENGINE
Page
4 - 3
4 - 4
4 - 5
Page
4 - 7
Page
4 - 9
4 - 10
4 - 11
4 - 12
4 - 13
4 - 14
4 - 15
4 - 16
CAMSHAFT, ROCKER ARMS AND VALVES
Page
4 - 18
4 - 19
4 - 20
4 - 21
4 - 22
4 - 23
4 - 24
4 - 25
4 - 26
4 - 27
4 - 28
4 - 29
4 - 30
4 - 31
4 - 32
4 - 33
4 - 34
RECOIL STARTER AND A.C. MAGNETO
4 - 35
4 - 36
4 - 37
4 - 38
4 - 39
4 - 40
4 - 41
4 - 42
Page
4 - 44
4 - 45
4 - 46
4 - 47
4 - 48
4 - 49
4 - 50
Page
4 - 52
4 - 53
4 - 54
4 - 55
4 - 56
4 - 57
4 - 58
4 - 59
4 - 60
4 - 61
4 - 62
4 - 63
4 - 64
Page
4 - 66
4 - 67
4 - 68
4 - 69
Page
Page
4 - 72
4 - 73
4 - 74
4 - 75
4 - 76
Page
4 - 78
4 - 79
4 - 80
4 - 81
4 - 82
4 - 83
4 - 84
4 - 85
4 - 86
4 - 87
5 - 1
COOLING SYSTEM
Page
5 - 3
5 - 4
Page
5 - 6
THERMOSTAT
5 - 7
5 - 8
5 - 9
5 - 10
5 - 11
Page
6 - 2
6 - 3
6 - 4
6 - 5
6 - 6
6 - 7
7 - 1
DRIVE TRAIN
7 - 2
7 - 3
7 - 4
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
Page
7 - 6
Page
Page
7 - 9
7 - 10
7 - 11
7 - 12
7 - 13
7 - 14
7 - 15
7 - 16
7 - 17
7 - 18
7 - 19
7 - 20
7 - 21
7 - 22
7 - 23
7 - 24
7 - 25
7 - 26
7 - 27
7 - 28
7 - 29
Page
8 - 2
8 - 3
8 - 4
8 - 5
Page
8 - 7
8 - 8
8 - 9
Page
8 - 11
8 - 12
8 - 13
8 - 14
8 - 15
8 - 16
8 - 17
8 - 18
Page
Page
8 - 21
Page
8 - 23
8 - 24
8 - 25
8 - 26
8 - 27
8 - 28
8 - 29
8 - 30
8 - 31
Page
8 - 33
8 - 34
Page
8 - 36
8 - 37
8 - 38
8 - 39
Page
8 - 41
8 - 42
8 - 43
8 - 44
8 - 45
8 - 46
Page
8 - 48
8 - 49
8 - 50
9 - 1
ELECTRICAL COMPONENTS
ELECTRICAL
ELECTRICAL COMPONENTS
9 - 2
Page
9 - 4
09
6
*
4 5
A
23
7
9 - 5
9 - 6
CHECKING THE BULBS AND BULB SOCKETS
9 - 7
9 - 8
9 - 9
EB802000
0Spark plug
9Ignition coil
9 - 10
9 - 11
9 - 12
9 - 13
9 - 14
9 - 15
EB803000
TStart switch
7Starter motor
6Starter relay
9 - 16
9 - 17
9 - 18
9 - 19
9 - 20
9 - 21
9 - 22
EB804000
2Rectifier/regulator
(GRAY)
9 - 23
9 - 24
9 - 25
EB805000
[Speedometer light
ZTail/brake light
UHeadlight
9 - 26
9 - 27
9 - 28
9 - 29
9 - 30
Page
9 - 32
EB806000
9 - 33
9 - 34
9 - 35
9 - 36
9 - 37
9 - 38
9 - 39
9 - 40
9 - 41
9 - 42
9 - 43
EFan motor
DThermo switch (radiator)
CCircuit breaker (fan motor)
9 - 44
9 - 45
9 - 46
9 - 47
9 - 48
KGear motor
JOn-command four-wheel drive switch
IFour-wheel drive fuse
9 - 49
9 - 50
9 - 51
10 - 1
STARTING FAILURE/HARD STARTING
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
10 - 2
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
10 - 3
FAULTY DRIVE TRAIN FAULTY DRIVE TRAIN
10 - 4
FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE FAULTY GEAR SHIFTING
FAULTY CLUTCH PERFORMANCE
10 - 5
FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE
OVERHEATING
FAULTY BRAKE
10 - 6
SHOCK ABSORBER MALFUNCTION
SHOCK ABSORBER MALFUNCTION/UNSTABLE HANDLING/LIGHTING SYSTEM
UNSTABLE HANDLING
YFM400FAR WIRING DIAGRAM
0
(GRAY)
ON
(DARK GRAY)