Important Information | Yamaha 5TE-F8197-10, LIT-11616-16-02

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person inspecting or repairing the machine.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:A NOTE provides key information to make procedures easier or clearer.

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

Contents

YFM400FAR YFM400FAR Important Information Manual Organization Exploded Diagrams GEN 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 Troubleshooting Chapter Chassis Front Arms and Front Shock Absorbers Chapter Electrical Starting FAILURE/HARD Starting Faulty Drive TrainFaulty Gear Shifting Faulty Clutch Performance Malfunction Faulty BrakeOverheating Poor Braking Effect Model Label Vehicle Identification Number Preparation 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 Imperial 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 Removing the seat and side panels Seat and Side Panels Front CARRIER, Front Bumper and Front Fender Removing the front carrier, frontBumper and front fender CHK ADJ First disconnect the negative lead Rear Carrier and Rear FenderRemoving the rear carrier and rear Fender CHK 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 Speed Adjusting 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 steps Starter 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 Loctite Checking the Ignition TimingEngine speed 1,450 ~ 1,550 r/min Recoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib Compression gauge YU-33223 Adapter YU-33223-3 Measuring the Compression Pressure Measuring 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 N Oil gallery bolt Nm 0.7 m kg, 5.1 ft lb Cleaning the AIR Filter 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 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 ROD Select lever shift rod Adjusting the Rear Brake Light Switch Direction 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 Boots Checking the Steering System Adjusting the TOE-IN Locknut rod end 40 Nm 4.0 m kg, 29 ft lb Toe-in = É È Adjusting the Front Shock Absorbers Adjusting the Rear Shock AbsorberChecking the Tires Maximum Loading Limit Tire CharacteristicsManufacturer Size Type Maxxis Cold tire Front Rear Checking and Lubricating the Cables Checking the Wheels Recommended lubricant Lithium soap base grease Lubricating the LEVERS, PEDAL, ETC Charging Method Checking the Battery Keep Batteries and Electrolyte OUT of Reach of Children Battery condition checking steps Open-circuit Charging time Or higher No charging is NecessaryExample YES Charging method using a variable voltage charger Charging method using a constant voltage charger Checking the Fuses Pocket tester YU-03112-C DescriptionQuantity Changing the Headlight Bulb Adjusting the Headlight Beams Changing 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 Leads Tighten Them to full torque Install all of the bolts/nuts and thenSpecifications Engine Mounting Bolts ENG Installing the Engine Removing the cylinder head Cylinder Head Rotor holding tool YU-01235 Removing the Cylinder Head Checking the Tappet Covers Checking the Timing Chain TensionerChecking the Camshaft Sprocket ENG Installing steps Installing the Cylinder Head Cap bolt timing chain tensioner 23 Nm 2.3 m kg, 17 ft lb Installation steps Tighten Camshaft sprocket bolt Valves and Valve Springs Removing the camshaft, rockerArms and valves Camshaft and Rocker Arms ENG 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 ION Installed length Spring tilt limit Inner 1.6 mm 0.06 in Outer Installing the Valves and Valve Springs Installing the Camshaft and Rocker Arms Piston Removing the cylinder and piston Checking the Timing Chain Guide Removing the PistonPiston pin puller set YU-01304 Do not use a hammer to drive the piston pin out 0016 Measurement steps 1st stepCylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272 05 mm Standard 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 Ring Installing the Piston Installing the Cylinder Removing the A.C. magneto ChapterMagneto ENG Disassembling the recoil starter Assembling the RecoilStarter Checking the A.C. Magneto Removing the A.C. MagnetoFlywheel puller YM-01404 Disassembling the Recoil Starter Bolts starter clutch 30 Nm 3.0 m kg, 22 ft lb Checking the Starter Clutch Checking the Starter Pulley Checking the Recoil StarterAssembling the Recoil Starter Sealant Quick Gasket ACC-11001-05-01 Yamaha bond No Installing the A.C. Magneto Use a rotor holding tool 2 to hold the starter pulley Sheaves Removing the primarySecondary sheaves Primary and Secondary For installation, reverse the removal Sheave Primary Sliding SheaveDisassembling the primary sliding Sheave Secondary Sheave Disassembling the secondaryAssembling the Secondary Removing steps Removing the Primary Secondary SheavesSheave holder YS-01880-A Disassembling the Secondary Sheave Free 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 Sheave Assembling the Secondary Sheave Assembling the Primary Sheave Nut 90 Nm 9.0 m kg, 65 ft lb Installing the Primary and Secondary Sheaves Clutch Removing the clutch Disassembling the clutch housing Removing the Clutch Clutch holding tool YM-91042Checking 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 filter ENG Crankcase Separating the crankcaseLever Crankcase Bearings Removing the crankcase bearingsPump Separation steps Removing the OIL Pump Drive GearRemoval steps Separating the Crankcase Checking the OIL Strainer and OIL Delivery Pipe Checking the Timing Chain and Guide Checking the Crankcase Checking the BearingsAssembling the Crankcase Installing the Shift Lever Tightening steps Installing the OIL Pump Drive Gear Crankshaft and Balancer CRANKSHAFT/INSTALLINGRemoving the crankshaft and oil Pump Disassembling the oil pump OIL Pump Removing the Crankshaft Crankcase separating tool YU-01135-AChecking the OIL Pump Crank width 62.95 ~ 63.00 mm 2.4783 ~ 2.4803 Checking the Crankshaft Installing 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 CAM Checking the Chain Checking the Secondary Shaft and Driven Sprocket Installing the Transmission Middle Drive Shaft Removing the middle drive shaftDrive and Driven Gear Shims Removing the middle driven shaft Middle Driven Shaft ENG Removing the Middle Driven Shaft Removing the Middle Drive Shaft Bearing retainer wrench YM-04128 Universal joint holder YM-04062 Checking the Pinion Gears Ring nut wrench YM-38404 Selecting 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 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 steps Gear lash measurement tool YM-01467 Removing the radiator Cool Cool Radiator cap tester YU-24460-01 Adapter YU-33984 Checking the Radiator Installing the Radiator Removing the thermostat Checking the Thermostat Installing the Thermostat Removing the water pump Disassembling the water pump Checking the Water Pump Disassembling the Water Pump Assembling the Water Pump Max. impeller shaft tilt 0.15 mm 0.006 Cool Removing the carburetor Carburetor Disassembling the carburetor Carb Checking the Carburetor Disassembling the Carburetor Carb Assembling the Carburetor Float height F.H mm 0.51 Measurement and adjustment steps Fuel level gauge YM-01312-A Adjusting the Fuel Level Following noises may indicate a mechanical defect Driv Troubleshooting Driv YES Troubleshooting chart Velocity joints and differential gear Removing the front constant Driv 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-01475 Ring gear shim left and right Thickness mm Adjusting differential gear lashReduce shim Increase shim Checking the Differential Gear Operation Rear Axle Gear assembly and drive shaftInstalling Removing the rear axle, final drive Disassembling the final drive gear Assembling the Final Drive GearDrive Roller Bearings Disassembling the Final Drive Gear Removing the Rear Axle Replacing 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 b Bearing thickness f 11.00 mm Ring gear shim thickness = c + d e + f Measure/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 mm Checking the Rear Axle Ring gear stopper clearance adjustmentShim Thickness mm Ring gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024 Checking the Final Drive Gear Checking the Drive Shaft Measurement 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 adjustment Installing the Final Drive Gear Assembling the Final Drive GearLithium-soap-based grease Nuts Bolts Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215 Hubs Front WheelsRemoving the front wheels Is no danger of it falling over Removing the rear wheels Rear Wheels Checking the Wheel Hubs Brake disc maximum deflection 15 mm 0.006 Installing the Wheel HubsInstalling the Wheels Checking the Brake Discs Install Nuts wheel Front Brake Pads Removing the front brake padsBrake Pads Brake pad wear limit 1 mm 0.04 Replacing the Front Brake Pads Brake caliper bleed screw 6 Nm 0.6 m kg, 4.3 ft lb Brake Master Cylinder Front Brake Master CylinderRemoving the front brake master Cylinder Master cylinder Disassembling the front brake Assembling the Front Brake Master Cylinder Checking the Master Cylinder Installing the Front Brake Master Cylinder Chas Front Brake Caliper Removing the front brake calipersCalipers Assembling the Front Brake Calipers Recommended brake component Replacement schedule Brake pads Disassembling the Front Brake CalipersChecking the Front Brake Calipers Assembling the Front Brake Calipers Installing 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 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 6.34 Bolt brake shoe plate 28 Nm 2.8 m kg, 20 ft lb Bolt camshaft lever Nm 0.9 m kg, 6.5 ft lb Chas Removing the handlebar Cylinder AssemblyBrake Switch Handlebar Checking the Handlebar Removing the Rear Brake SwitchInstalling the Handlebar Installing the Rear Brake Lever Installing the Master Cylinder Assembly Steering Stem Removing the steering stemGuide Bearing Retainer Checking the Steering Stem Installing the Bearing RetainerInstalling the Cable Guide Removing the Bearing Retainer Knuckles TIE Rods and Steering KnucklesRemoving the tie rods and steering Knuckles Chas 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 front Absorber Arms and Front Shock Checking the Front Arms Removing the Front Arms Replacement 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 absorber Swingarm Housing Removing 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 Housing Electrical 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 Bulbs Pocket 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 F Spark plug gap Minimum spark gap 6.0 mm 0.24Spark 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 C0NTINUITY Main switch Refer to Checking the Switches Properly connect the ignition system Replace the CDI unit Correct Poor Connection System Electric Starting System Elec If the Starter Motor Fails to Operate Does not Turn Turns Incorrect Correct Motor Starter MotorRemoving the starter motor Disassembling the starter motor Checking 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 0.20 Charging Continuity No Continuity If the Battery is not Charged Charging voltage Meets SpecificationOUT Specification OUT of Specification Headlight 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 Continuity 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 Test Coolant temperature Thermo switch Continuity Step Less than 120 ± 3 C 248 ± 5.4 F235.4 F BAD Condition Good Condition Correct OUT of Specification Meets System Cooling If the FAN Motor does not Move Circuit breaker resistance Zero Ω at 20 C 68 F Meets Specification Does not Turn Less 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 System Poor Medium and HIGH-SPEED Performance Compression System Faulty Drive Train Engine Operates but Machine will not Move Hard ShiftingShift Lever does not Move Jumps OUT of Gear Poor Speed Performance OverheatingPoor Braking Effect Bulb Burnt OUT MalfunctionUnstable Handling Headlight Dark YFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan