YFM400FAR
YFM400FAR
Important Information
Exploded Diagrams
Manual Organization
GEN Spec Info CHK ENG ADJ
Table of Contents
Contents Chapter General Information
Seat and Side Panels
Introduction
Fuel Tank
Chapter Engine
Page
Chapter Cooling System
Troubleshooting
Rear AXLE/FINAL Drive Gear and Drive Shaft
Chapter Chassis
Chapter Electrical
Front Arms and Front Shock Absorbers
Faulty Clutch Performance
Faulty Drive Train
Faulty Gear Shifting
Starting FAILURE/HARD Starting
Poor Braking Effect
Faulty Brake
Overheating
Malfunction
Vehicle Identification Number
Model Label
Replacement Parts
Preparation for Removal Procedures
GASKETS, OIL Seals and O-RINGS
Bearings and OIL Seals
Lock WASHERS/PLATES and Cotter Pins
Circlips
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
Mikuni
Maxxis
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/JIDECO
5ND/NIPPON Thermostat
Metric Multiplier Imperial
Conversion Table
Lubrication 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 panels
Removing the front carrier, front
Front CARRIER, Front Bumper and Front Fender
Bumper and front fender
CHK ADJ
Fender
Rear Carrier and Rear Fender
Removing the rear carrier and rear
First disconnect the negative lead
CHK ADJ
Removing the fuel tank
Fuel Tank
Bumper and Front Fender
Removing the footrest boards
Adjusting the Valve Clearance
Adjusting the Valve Clearance
Tappet adjusting tool YM-08035
Adjustment steps
Locknut 20 Nm 2.0 m kg, 14 ft lb
Adjusting the Idling Speed
Engine idling speed 1,450 ~ 1,550 r/min
Turning Idling speed becomes Higher Turning out Lower
Adjusting the Throttle Lever Free Play
Throttle lever free play ~ 5 mm 0.12 ~ 0.20
Adjustment steps First step
Second step
Adjusting the Speed Limiter
Speed limiter length 12 mm 0.47
Speed limiter length adjustment steps
Adjusting the Starter Cable
Starter plunger stroke distance 15 mm 0.59
Standard spark plug DR8EA/NGK
Checking the Spark Plug
Spark 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 Timing
Engine speed 1,450 ~ 1,550 r/min
Loctite
Measuring the Compression Pressure
Compression gauge YU-33223 Adapter YU-33223-3
Measuring the Compression Pressure
Checking the Engine OIL Level
Recommended oil Follow the left chart
Do not allow foreign material to enter the crankcase
Changing the Engine OIL
Replacement steps
Oil filter wrench YU-38411
Cautio N
Oil filter cartridge 17 Nm 1.7 m kg, 12 ft lb
Cleaning the AIR Filter
Oil gallery bolt Nm 0.7 m kg, 5.1 ft lb
Cleaning 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 Temperature
Belt 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 Brake
Rear 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 Level
DOT
Brake pad wear limit a 1 mm 0.04
Checking the Front Brake Pads
Checking the Rear Brake Shoes
Checking the Brake Hoses
Air bleeding steps
Bleeding the Hydraulic Brake System
Bleed screw Nm 0.6 m kg, 4.3 ft lb
Adjusting the Select Lever Control Cable and Shift ROD
Adjustment steps Control cable
Adjusting the Rear Brake Light Switch
Select lever shift rod
Checking the Final Gear OIL Level
Direction a Brake light comes on Sooner Direction b Later
Recommended 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 OIL
Adjusting the TOE-IN
Checking the Steering System
Toe-in = É È
Locknut rod end 40 Nm 4.0 m kg, 29 ft lb
Adjusting the Rear Shock Absorber
Adjusting the Front Shock Absorbers
Checking the Tires
Maxxis
Tire Characteristics
Manufacturer Size Type
Maximum Loading Limit
Cold tire Front Rear
Checking the Wheels
Checking and Lubricating the Cables
Lubricating the LEVERS, PEDAL, ETC
Recommended lubricant Lithium soap base grease
Checking the Battery
Charging Method
Battery condition checking steps
Keep Batteries and Electrolyte OUT of Reach of Children
Or higher No charging is Necessary
Open-circuit Charging time
Example
Charging method using a variable voltage charger
YES
Charging method using a constant voltage charger
Checking the Fuses
Description
Pocket tester YU-03112-C
Quantity
Adjusting the Headlight Beams
Changing the Headlight Bulb
Changing the Headlight Bulb
Removing the air ducts, muffler
AIR DUCTS, Muffler and Exhaust Pipe
Exhaust pipe
ENG
Removing the select lever unit
Select Lever Unit and Coolant Reservoir
Coolant reservoir
Hoses and Leads
Removing the hoses and leads
Engine Mounting Bolts
Install all of the bolts/nuts and then
Specifications
Tighten Them to full torque
ENG
Installing the Engine
Removing the cylinder head
Cylinder Head
Removing the Cylinder Head
Rotor holding tool YU-01235
Checking the Timing Chain Tensioner
Checking the Tappet Covers
Checking the Camshaft Sprocket
ENG
Installing the Cylinder Head
Installing steps
Installation steps
Cap bolt timing chain tensioner 23 Nm 2.3 m kg, 17 ft lb
Tighten Camshaft sprocket bolt
Camshaft and Rocker Arms
Removing the camshaft, rocker
Arms and valves
Valves and Valve Springs
ENG
Removing the Camshaft and Rocker Arms
Slide hammer set YU-01083-A Slide hammer bolt M6 Weight
Removing the Valves and Valve Springs
Checking the Camshaft
Valve spring compressor YM-04019
Checking 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 steps
Installed length
Installing the Valves and Valve Springs
Spring tilt limit Inner 1.6 mm 0.06 in Outer
Installing the Camshaft and Rocker Arms
Removing the cylinder and piston
Piston
Do not use a hammer to drive the piston pin out
Removing the Piston
Piston pin puller set YU-01304
Checking the Timing Chain Guide
05 mm
Measurement steps 1st step
Cylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272
0016
Side clearance
3rd step
Checking the Piston Rings
Standard Limit Top 03 ~ 0.08 mm 13 mm Ring
2nd ~ 0.60 mm 95 mm Ring
End gap Standard Limit
~ 0.40 mm 65 mm Ring
~ 0.7 mm Ring
Installing the Piston
Installing the Cylinder
Chapter
Removing the A.C. magneto
Magneto
ENG
Assembling the Recoil
Disassembling the recoil starter
Starter
Disassembling the Recoil Starter
Removing the A.C. Magneto
Flywheel puller YM-01404
Checking the A.C. Magneto
Checking the Starter Clutch
Bolts starter clutch 30 Nm 3.0 m kg, 22 ft lb
Checking the Recoil Starter
Checking the Starter Pulley
Assembling the Recoil Starter
Installing the A.C. Magneto
Sealant Quick Gasket ACC-11001-05-01 Yamaha bond No
Use a rotor holding tool 2 to hold the starter pulley
Primary and Secondary
Removing the primary
Secondary sheaves
Sheaves
For installation, reverse the removal
Sheave
Primary Sliding Sheave
Disassembling the primary sliding
Sheave
Disassembling the secondary
Secondary Sheave
Assembling the Secondary
Disassembling the Secondary Sheave
Removing the Primary Secondary Sheaves
Sheave holder YS-01880-A
Removing steps
Checking the Secondary Sheave
Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16
Checking the Primary Sheave
Free length 121.4 mm 4.78 Limit 115.33 mm 4.54
Assembling the Primary Sheave
Assembling the Secondary Sheave
Nut 90 Nm 9.0 m kg, 65 ft lb
Installing the Primary and Secondary Sheaves
Removing the clutch
Clutch
Disassembling the clutch housing
Clutch holding tool YM-91042
Removing the Clutch
Checking the Clutch
Installing the Clutch
Install Dowel pins Gasket New Clutch housing assembly
Chain and oil filter
Starter MOTOR, Timing Chain and OIL Filter
Removing the starter motor, timing
OIL Pump Drive Gear
ENG
Separating the crankcase
Crankcase
Lever
Removing the crankcase bearings
Crankcase Bearings
Pump
Separating the Crankcase
Removing the OIL Pump Drive Gear
Removal steps
Separation steps
Checking the Timing Chain and Guide
Checking the OIL Strainer and OIL Delivery Pipe
Checking the Bearings
Checking the Crankcase
Assembling the Crankcase
Installing the Shift Lever
Installing the OIL Pump Drive Gear
Tightening steps
Pump
CRANKSHAFT/INSTALLING
Removing the crankshaft and oil
Crankshaft and Balancer
OIL Pump
Disassembling the oil pump
Crankcase separating tool YU-01135-A
Removing the Crankshaft
Checking the OIL Pump
Checking the Crankshaft
Crank width 62.95 ~ 63.00 mm 2.4783 ~ 2.4803
Installing the Crankshaft and Balancer
Removing the transmission
ENG
Checking the Shift CAM
Checking the Shift Forks
Do not attempt to straighten a bent guide bar
Checking the Transmission
Checking the Secondary Shaft and Driven Sprocket
Checking the Chain
Installing the Transmission
Removing the middle drive shaft
Middle Drive Shaft
Drive and Driven Gear Shims
Middle Driven Shaft
Removing the middle driven shaft
ENG
Removing the Middle Drive Shaft
Removing the Middle Driven Shaft
Universal joint holder YM-04062
Bearing retainer wrench YM-04128
Ring nut wrench YM-38404
Checking the Pinion Gears
Selection steps
Selecting the Middle Drive and Driven Gear Shims
Middle drive pinion gear shim thickness a = c a b
Middle drive pinion gear shim Thickness mm
Hundredths Round value 5, 6
Middle 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 Shaft
Measuring the Middle Gear Backlash
Pinion gear fix clamp YM-04129
Gear lash measurement tool YM-01467
Cool
Removing the radiator
Cool
Checking the Radiator
Radiator cap tester YU-24460-01 Adapter YU-33984
Installing the Radiator
Removing the thermostat
Installing the Thermostat
Checking the Thermostat
Removing the water pump
Disassembling the water pump
Disassembling the Water Pump
Checking the Water Pump
Max. impeller shaft tilt 0.15 mm 0.006
Assembling the Water Pump
Cool
Removing the carburetor
Disassembling the carburetor
Carburetor
Carb
Disassembling the Carburetor
Checking the Carburetor
Carb
Float height F.H mm 0.51 Measurement and adjustment steps
Assembling the Carburetor
Adjusting the Fuel Level
Fuel level gauge YM-01312-A
Driv
Following noises may indicate a mechanical defect
Troubleshooting Driv
Troubleshooting chart
YES
Removing the front constant
Velocity joints and differential gear
Driv
Joints
Disassembling the constant velocity
Constant Velocity Joints
Differential gear
Driv
Always use new boot bands
Removing the Differential Gear Assembly
Checking the Constant Velocity Joints
Checking the Differential Gear
Molybdenum disulfide grease 40 g 1.4 oz per dust boot
Assembling the Front Constant Velocity Joints
Assembling the Differential Gear
Gear lash measurement tool YM-01475
Differential gear lash 10 ~ 0.50 mm 0.004 ~ 0.020
Increase shim
Adjusting differential gear lash
Reduce shim
Ring gear shim left and right Thickness mm
Checking the Differential Gear Operation
Removing the rear axle, final drive
Gear assembly and drive shaft
Installing
Rear Axle
Disassembling the final drive gear
Gear
Assembling the Final Drive
Drive Roller Bearings
Removing the Rear Axle
Disassembling the Final Drive Gear
Replacing the Final Drive Roller Bearings
Final drive pinion gear shim thickness a = a b
Positioning the Final Drive Pinion Gear and Ring Gear
Final drive pinion gear shim selection
Hundredths Rounded value 5, 6
Ring gear shim thickness = c + d e + f
Bearing thickness f 11.00 mm
Measure/select Ring gear thrust clearance C
Thrust washer Thickness mm
Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008
Thrust washer selection steps
Ring gear stopper shim selection
Ring gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024
Ring gear stopper clearance adjustment
Shim Thickness mm
Checking the Rear Axle
Checking the Drive Shaft
Checking the Final Drive Gear
Final gear lash measurement
Measurement and Adjusting the Final Gear Lash
Final 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 washer
Assembling the Final Drive Gear
Installing the Final Drive Gear
Lithium-soap-based grease
Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215
Nuts Bolts
Is no danger of it falling over
Front Wheels
Removing the front wheels
Hubs
Rear Wheels
Removing the rear wheels
Checking the Wheel Hubs
Checking the Brake Discs
Installing the Wheel Hubs
Installing the Wheels
Brake disc maximum deflection 15 mm 0.006
Install Nuts wheel
Removing the front brake pads
Front Brake Pads
Brake Pads
Replacing the Front Brake Pads
Brake pad wear limit 1 mm 0.04
Brake caliper bleed screw 6 Nm 0.6 m kg, 4.3 ft lb
Cylinder
Front Brake Master Cylinder
Removing the front brake master
Brake Master Cylinder
Disassembling the front brake
Master cylinder
Checking the Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Chas
Removing the front brake calipers
Front Brake Caliper
Calipers
Calipers
Assembling the Front Brake
Disassembling the Front Brake Calipers
Recommended brake component Replacement schedule Brake pads
Checking the Front Brake Calipers
Installing the Front Brake Calipers
Assembling the Front Brake Calipers
Fill 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 Brake
Brake shoe lining thickness limit 2.0 mm 0.08
Lithium-soap base grease
Bolt camshaft lever Nm 0.9 m kg, 6.5 ft lb
Bolt brake shoe plate 28 Nm 2.8 m kg, 20 ft lb
Chas
Handlebar
Cylinder Assembly
Brake Switch
Removing the handlebar
Installing the Rear Brake Lever
Removing the Rear Brake Switch
Installing the Handlebar
Checking the Handlebar
Installing the Master Cylinder Assembly
Removing the steering stem
Steering Stem
Guide
Bearing Retainer
Removing the Bearing Retainer
Installing the Bearing Retainer
Installing the Cable Guide
Checking the Steering Stem
Knuckles
TIE Rods and Steering Knuckles
Removing the tie rods and steering
Knuckles
Chas
Checking the TIE Rods
Removing the Steering Knuckles
Checking the Steering Knuckles
Chas
Eye protection is recommended when using striking tools
Installing the TIE Rods
Removing the front arms and front
Shock absorbers
Arms and Front Shock
Absorber
Removing the Front Arms
Checking the Front Arms
Replacement steps
Checking the Front Shock Absorber
Nut 45 Nm 4.5 m kg, 32 ft lb
Installing the Front Arms and Front Shock Absorber
Nut 30 Nm 3.0 m kg, 22 ft lb
Removing the rear shock absorber
Swingarm
Housing
Swingarm
Nut swingarm 82 Nm 8.2 m kg, 59 ft lb
Removing the Swingarm
Checking the Rear Shock Absorber
Installing the Rubber Boot
Checking the Rubber Boot
Checking the Swingarm
Installing the Rear Axle Housing
Nut 63 Nm 6.3 m kg, 45 ft lb Loctite Bolt Loctite Nut
Electrical Components Elec
Checking a Switch Shown in the Manual
Checking a Switch
Example chart shows that
Elec +
Checking the Switch Continuity
Elec
Types of Bulbs
Checking the Condition of the Bulbs
Pocket tester YU-03112-C
Checking the Condition of the Bulb Sockets
Circuit Diagram
Open-circuit voltage Or more at 20 C 68 F
Troubleshooting
Procedure
Standard spark plug
Minimum spark gap 6.0 mm 0.24
Spark plug gap
Spark plug cap resistance 10 kΩ at 20 C 68 F
C0NTINUITY
Both Meet Specification
Correct OUT of Specification
Primary coil resistance 18 ~ 0.28 Ω at 20 C 68 F
Main switch Refer to Checking the Switches
Correct Poor Connection
Properly connect the ignition system Replace the CDI unit
System Electric Starting System Elec
If the Starter Motor Fails to Operate
Turns
Does not Turn
Incorrect Correct
Disassembling the starter motor
Starter Motor
Removing the starter motor
Motor
Outside diameter 28 mm 1.10 Wear limit 27 mm 1.06
Checking the Starter Motor
Mica undercut 0.7 mm 0.03
Brush length 12.5 mm 0.49 Wear limit 5 mm 0.20
Assembling the Starter Motor
Charging
If the Battery is not Charged
Continuity No Continuity
OUT of Specification
Meets Specification
OUT Specification
Charging voltage
Headlight 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 lead
Tester + 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 Step
235.4 F
Good Condition
BAD Condition
Correct
OUT of Specification Meets
Cooling
System
If the FAN Motor does not Move
Meets Specification Does not Turn
Circuit breaker resistance Zero Ω at 20 C 68 F
176 ± 5.4 F
Less than 86 ± 3 C 186.8 ± 5.4 F
Good
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 System
Compression System
Poor Medium and HIGH-SPEED Performance
Faulty Drive Train
Jumps OUT of Gear
Hard Shifting
Shift Lever does not Move
Engine Operates but Machine will not Move
Overheating
Poor Speed Performance
Poor Braking Effect
Headlight Dark
Malfunction
Unstable Handling
Bulb Burnt OUT
YFM400FAR Wiring Diagram
Shingai Iwata Shizuoka Japan