Incorrect Correct | Yamaha 5TE-F8197-10, LIT-11616-16-02 manual

ELECTRIC STARTING SYSTEM

ELEC

–

+

* C0NTINUITY

5.Main switch

Refer to “CHECKING THE SWITCHES”.

INCORRECT

CORRECT

6.Engine stop switch

Refer to “CHECKING THE SWITCHES”.

Replace the main switch.

INCORRECT

CORRECT

7.Start switch

Refer to “CHECKING THE SWITCHES”.

CORRECT

EB803028

8.Wiring connections

●Check the connections of the entire starting system.

Refer to “CIRCUIT DIAGRAM”.

Replace the handlebar switch (left).

INCORRECT

Replace the handlebar switch (left).

POOR CONNECTION

Properly connect the starting system.

9 - 18

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

Contents

YFM400FAR YFM400FAR Important Information Manual Organization Exploded Diagrams GEN 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 Troubleshooting Chapter Chassis Front Arms and Front Shock Absorbers Chapter Electrical Faulty Gear Shifting Faulty Drive TrainFaulty Clutch Performance Starting FAILURE/HARD Starting Overheating Faulty BrakePoor Braking Effect Malfunction Model Label Vehicle Identification Number Replacement 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 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 Removing the front carrier, front Front CARRIER, Front Bumper and Front FenderBumper and front fender CHK ADJ Removing the rear carrier and rear Rear Carrier and Rear FenderFender First disconnect the negative lead CHK 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 Speed Turning 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 steps Starter 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 Engine speed 1,450 ~ 1,550 r/min Checking the Ignition TimingRecoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib Loctite Compression gauge YU-33223 Adapter YU-33223-3 Measuring the Compression Pressure Measuring 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 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 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 ROD Select lever shift rod Adjusting the Rear Brake Light Switch Checking 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 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 Rear Shock Absorber Adjusting the Front Shock AbsorbersChecking the Tires Manufacturer Size Type Tire CharacteristicsMaxxis Maximum Loading Limit 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 Or higher No charging is Necessary Open-circuit Charging timeExample YES Charging method using a variable voltage charger Charging method using a constant voltage charger Checking the Fuses Description Pocket tester YU-03112-CQuantity Changing the Headlight Bulb Adjusting the Headlight Beams Changing 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 Leads Specifications Install all of the bolts/nuts and thenEngine Mounting Bolts Tighten Them to full torque ENG Installing the Engine Removing the cylinder head Cylinder Head Rotor holding tool YU-01235 Removing the Cylinder Head Checking the Timing Chain Tensioner Checking the Tappet CoversChecking 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 Arms and valves Removing the camshaft, rockerCamshaft and Rocker Arms Valves and Valve Springs ENG 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 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 Piston pin puller set YU-01304 Removing the PistonDo not use a hammer to drive the piston pin out Checking the Timing Chain Guide Cylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272 Measurement steps 1st step05 mm 0016 Checking the Piston Rings 3rd stepSide clearance Standard Limit Top 03 ~ 0.08 mm 13 mm Ring ~ 0.40 mm 65 mm Ring End gap Standard Limit2nd ~ 0.60 mm 95 mm Ring ~ 0.7 mm Ring Installing the Piston Installing the Cylinder Chapter Removing the A.C. magnetoMagneto ENG Assembling the Recoil Disassembling the recoil starterStarter Flywheel puller YM-01404 Removing the A.C. MagnetoDisassembling the Recoil Starter Checking the A.C. Magneto Bolts starter clutch 30 Nm 3.0 m kg, 22 ft lb Checking the Starter Clutch Checking the Recoil Starter Checking the Starter PulleyAssembling 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 Secondary sheaves Removing the primaryPrimary and Secondary Sheaves For installation, reverse the removal Disassembling the primary sliding Primary Sliding SheaveSheave Sheave Disassembling the secondary Secondary SheaveAssembling the Secondary Sheave holder YS-01880-A Removing the Primary Secondary SheavesDisassembling the Secondary Sheave Removing steps Checking the Primary Sheave Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16Checking the Secondary Sheave Free length 121.4 mm 4.78 Limit 115.33 mm 4.54 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 Clutch holding tool YM-91042 Removing the ClutchChecking the Clutch Installing the Clutch Install Dowel pins Gasket New Clutch housing assembly Removing the starter motor, timing Starter MOTOR, Timing Chain and OIL FilterChain and oil filter OIL Pump Drive Gear ENG Separating the crankcase CrankcaseLever Removing the crankcase bearings Crankcase BearingsPump Removal steps Removing the OIL Pump Drive GearSeparating the Crankcase Separation steps Checking the OIL Strainer and OIL Delivery Pipe Checking the Timing Chain and Guide Checking the Bearings Checking the CrankcaseAssembling the Crankcase Installing the Shift Lever Tightening steps Installing the OIL Pump Drive Gear Removing the crankshaft and oil CRANKSHAFT/INSTALLINGPump Crankshaft and Balancer Disassembling the oil pump OIL Pump Crankcase separating tool YU-01135-A Removing the CrankshaftChecking 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 Do not attempt to straighten a bent guide bar Checking the Shift ForksChecking the Shift CAM Checking the Transmission Checking the Chain Checking the Secondary Shaft and Driven Sprocket Installing the Transmission Removing the middle drive shaft 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 Selection 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 Measuring the Middle Gear Backlash Installing the Middle Drive ShaftMiddle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement steps Pinion gear fix clamp YM-04129 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 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-01475 Reduce shim Adjusting differential gear lashIncrease shim Ring gear shim left and right Thickness mm Checking the Differential Gear Operation Installing Gear assembly and drive shaftRemoving the rear axle, final drive Rear Axle Disassembling the final drive gear Gear Assembling the Final DriveDrive Roller Bearings Disassembling the Final Drive Gear Removing the Rear Axle Replacing the Final Drive Roller Bearings Final drive pinion gear shim selection Positioning the Final Drive Pinion Gear and Ring GearFinal drive pinion gear shim thickness a = a b Hundredths Rounded value 5, 6 Bearing thickness f 11.00 mm Ring gear shim thickness = c + d e + f Measure/select Ring gear thrust clearance C Thrust washer selection steps Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008Thrust washer Thickness mm Ring gear stopper shim selection Shim Thickness mm Ring gear stopper clearance adjustmentRing gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024 Checking the Rear Axle Checking the Final Drive Gear Checking the Drive Shaft Final 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 adjustment Assembling the Final Drive Gear Installing the Final Drive GearLithium-soap-based grease Nuts Bolts Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215 Removing the front wheels Front WheelsIs no danger of it falling over Hubs Removing the rear wheels Rear Wheels Checking the Wheel Hubs Installing the Wheels Installing the Wheel HubsChecking the Brake Discs Brake disc maximum deflection 15 mm 0.006 Install Nuts wheel Removing the front brake pads 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 Removing the front brake master Front Brake Master CylinderCylinder 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 Removing the front brake calipers Front Brake CaliperCalipers Assembling the Front Brake Calipers Disassembling the Front Brake Calipers Recommended brake component Replacement schedule Brake padsChecking 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 Brake shoe lining thickness limit 2.0 mm 0.08 Installing the Rear BrakeBrake drum inside diameter limit maximum 161 mm 6.34 Lithium-soap base grease 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 Brake Switch Cylinder AssemblyHandlebar Removing the handlebar Installing the Handlebar Removing the Rear Brake SwitchInstalling the Rear Brake Lever Checking the Handlebar Installing the Master Cylinder Assembly Removing the steering stem Steering StemGuide Bearing Retainer Installing the Cable Guide Installing the Bearing RetainerRemoving the Bearing Retainer Checking the Steering Stem Removing the tie rods and steering TIE Rods and Steering KnucklesKnuckles Knuckles Chas 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 front Absorber Arms and Front Shock Checking the Front Arms Removing 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 AbsorberNut 30 Nm 3.0 m kg, 22 ft lb Swingarm Removing the rear shock absorber Swingarm Housing Nut 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 Housing Electrical 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 Bulbs Pocket tester YU-03112-C Checking the Condition of the Bulb Sockets Circuit Diagram Procedure TroubleshootingOpen-circuit voltage Or more at 20 C 68 F Standard spark plug Minimum spark gap 6.0 mm 0.24 Spark plug gapSpark plug cap resistance 10 kΩ at 20 C 68 F Correct OUT of Specification Both Meet SpecificationC0NTINUITY Primary coil resistance 18 ~ 0.28 Ω at 20 C 68 F 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 Removing the starter motor Starter MotorDisassembling the starter motor Motor Outside 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 0.20 Charging Continuity No Continuity If the Battery is not Charged OUT Specification Meets SpecificationOUT of Specification Charging voltage 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 Less than 120 ± 3 C 248 ± 5.4 F Test Coolant temperature Thermo switch Continuity Step235.4 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 176 ± 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 System Poor Medium and HIGH-SPEED Performance Compression System Faulty Drive Train Shift Lever does not Move Hard ShiftingJumps OUT of Gear Engine Operates but Machine will not Move Overheating Poor Speed PerformancePoor Braking Effect Unstable Handling MalfunctionHeadlight Dark Bulb Burnt OUT YFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan