Shingai Iwata Shizuoka Japan | Yamaha LIT-11616-16-02, 5TE-F8197-10

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

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Yamaha LIT-11616-16-02, 5TE-F8197-10 service manual Shingai Iwata Shizuoka Japan

Contents

YFM400FAR YFM400FAR Important Information Exploded Diagrams Manual Organization 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 Troubleshooting Rear AXLE/FINAL Drive Gear and Drive Shaft Chapter Chassis Chapter Electrical Front Arms and Front Shock Absorbers Faulty Clutch Performance Faulty Drive TrainFaulty Gear Shifting Starting FAILURE/HARD Starting Poor Braking Effect Faulty BrakeOverheating Malfunction Vehicle Identification Number Model Label 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 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 Front CARRIER, Front Bumper and Front Fender Removing the front carrier, frontBumper and front fender CHK ADJ Fender Rear Carrier and Rear FenderRemoving the rear carrier and rear First disconnect the negative lead 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 Adjusting the Idling Speed Engine idling speed 1,450 ~ 1,550 r/min 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 Speed limiter length adjustment steps Adjusting the Starter Cable 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 Recoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib Checking the Ignition TimingEngine speed 1,450 ~ 1,550 r/min Loctite Measuring the Compression Pressure Compression gauge YU-33223 Adapter YU-33223-3 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 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 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 Adjusting the Select Lever Control Cable and Shift ROD Adjustment steps Control cable Adjusting the Rear Brake Light Switch Select lever shift rod 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 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 Front Shock Absorbers Adjusting the Rear Shock AbsorberChecking the Tires Maxxis Tire CharacteristicsManufacturer 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 Open-circuit Charging time Or higher No charging is NecessaryExample Charging method using a variable voltage charger YES Charging method using a constant voltage charger Checking the Fuses Pocket tester YU-03112-C DescriptionQuantity Adjusting the Headlight Beams Changing the Headlight Bulb 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 Hoses and Leads Removing the hoses and leads Engine Mounting Bolts Install all of the bolts/nuts and thenSpecifications 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 Tappet Covers Checking the Timing Chain TensionerChecking 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, rockerArms and valves Valves and Valve Springs 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 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 PistonPiston pin puller set YU-01304 Checking the Timing Chain Guide 05 mm Measurement steps 1st stepCylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.3272 0016 Side clearance 3rd stepChecking 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 Removing the A.C. magneto ChapterMagneto ENG Disassembling the recoil starter Assembling the RecoilStarter Disassembling the Recoil Starter Removing the A.C. MagnetoFlywheel 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 Starter Pulley Checking the Recoil StarterAssembling 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 primarySecondary sheaves Sheaves For installation, reverse the removal Sheave Primary Sliding SheaveDisassembling the primary sliding Sheave Secondary Sheave Disassembling the secondaryAssembling the Secondary Disassembling the Secondary Sheave Removing the Primary Secondary SheavesSheave holder YS-01880-A Removing steps Checking the Secondary Sheave Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16Checking 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 Removing the Clutch Clutch holding tool YM-91042Checking the Clutch Installing the Clutch Install Dowel pins Gasket New Clutch housing assembly Chain and oil filter Starter MOTOR, Timing Chain and OIL FilterRemoving the starter motor, timing OIL Pump Drive Gear ENG Crankcase Separating the crankcaseLever Crankcase Bearings Removing the crankcase bearingsPump Separating the Crankcase Removing the OIL Pump Drive GearRemoval steps Separation steps Checking the Timing Chain and Guide Checking the OIL Strainer and OIL Delivery Pipe Checking the Crankcase Checking the BearingsAssembling the Crankcase Installing the Shift Lever Installing the OIL Pump Drive Gear Tightening steps Pump CRANKSHAFT/INSTALLINGRemoving the crankshaft and oil Crankshaft and Balancer OIL Pump Disassembling the oil pump Removing the Crankshaft Crankcase separating tool YU-01135-AChecking 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 ForksDo not attempt to straighten a bent guide bar Checking the Transmission Checking the Secondary Shaft and Driven Sprocket Checking the Chain Installing the Transmission Middle Drive Shaft Removing the middle drive shaftDrive 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 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 Middle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement steps Installing the Middle Drive ShaftMeasuring 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 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 Gear lash measurement tool YM-01475 Differential gear lash 10 ~ 0.50 mm 0.004 ~ 0.020 Increase shim Adjusting differential gear lashReduce shim Ring gear shim left and right Thickness mm Checking the Differential Gear Operation Removing the rear axle, final drive Gear assembly and drive shaftInstalling Rear Axle Disassembling the final drive gear Assembling the Final Drive GearDrive 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 GearFinal 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 ~ 0.008Thrust 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 adjustmentShim Thickness mm Checking the Rear Axle Checking the Drive Shaft Checking the Final Drive Gear Measurement and Adjusting the Final Gear Lash Final gear lash measurementFinal 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 Installing the Final Drive Gear Assembling the Final Drive GearLithium-soap-based grease Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215 Nuts Bolts Is no danger of it falling over Front WheelsRemoving the front wheels Hubs Rear Wheels Removing the rear wheels Checking the Wheel Hubs Checking the Brake Discs Installing the Wheel HubsInstalling the Wheels Brake disc maximum deflection 15 mm 0.006 Install Nuts wheel Front Brake Pads Removing the front brake padsBrake 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 CylinderRemoving 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 Front Brake Caliper Removing the front brake calipersCalipers Calipers Assembling the Front Brake Recommended brake component Replacement schedule Brake pads Disassembling the Front Brake CalipersChecking 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 BrakeBrake 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 AssemblyBrake Switch Removing the handlebar Installing the Rear Brake Lever Removing the Rear Brake SwitchInstalling the Handlebar Checking the Handlebar Installing the Master Cylinder Assembly Steering Stem Removing the steering stemGuide Bearing Retainer Removing the Bearing Retainer Installing the Bearing RetainerInstalling the Cable Guide Checking the Steering Stem 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 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 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 Removing the rear shock absorber Swingarm Housing Swingarm 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 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 Checking a Switch Shown in the ManualExample 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 TroubleshootingProcedure Standard spark plug Spark plug gap Minimum spark gap 6.0 mm 0.24Spark plug cap resistance 10 kΩ at 20 C 68 F C0NTINUITY Both Meet SpecificationCorrect 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 MotorRemoving the starter motor Motor Checking the Starter Motor Outside diameter 28 mm 1.10 Wear limit 27 mm 1.06Mica 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 SpecificationOUT 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 Test Coolant temperature Thermo switch Continuity Step Less than 120 ± 3 C 248 ± 5.4 F235.4 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 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 Fuel System Electrical System Compression System Poor Medium and HIGH-SPEED Performance Faulty Drive Train Jumps OUT of Gear Hard ShiftingShift Lever does not Move Engine Operates but Machine will not Move Poor Speed Performance OverheatingPoor Braking Effect Headlight Dark MalfunctionUnstable Handling Bulb Burnt OUT YFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan