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Yamaha 5TE-F8197-10, LIT-11616-16-02 service manual 9 - 40

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ELEC

SIGNAL SYSTEM

C0NTINUITY

GOOD

CONDITION

WARNING

Handle the thermo switch (cylinder head)

with special care.

Never subject it to a strong shock or allow

it to be dropped. Should it be dropped, it

must be replaced.

Thermo switch (cylinder head):

8 Nm (0.8 m • kg, 5.8 ft • lb)

Three bond sealock® #10

BAD CONDITION

Replace the thermo switch (cylinder head).

3.Voltage

●Connect the pocket tester (DC 20 V) to the

bulb socket connector.

Tester (+) lead → Red/Black terminal 1

Tester (–) lead → White/Blue terminal 2

MEETS

SPECIFICATION

●Turn the main switch to “ON”.

●Check the voltage (12 V).

OUT OF SPECIFICATION

The wiring circuit from the main switch to the

bulb socket connector is faulty, repair it.

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)