Manual Organization, Exploded Diagrams | Yamaha LIT-11616-16-02

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1.An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2.Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6.The meanings of the symbol marks are given on the next page.

4.A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5.For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

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Yamaha LIT-11616-16-02, 5TE-F8197-10 service manual Manual Organization, Exploded Diagrams

Contents

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 IntroductionFuel 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 Drive Train Faulty Gear ShiftingFaulty Clutch Performance Starting FAILURE/HARD Starting Faulty Brake OverheatingPoor Braking Effect Malfunction Vehicle Identification Number Model Label 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 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 FenderBumper and front fender CHK ADJ Rear Carrier and Rear Fender Removing the rear carrier and rearFender 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 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 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 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 PlugSpark plug gap ~ 0.7 mm 0.024 ~ 0.028 Checking the Ignition Timing Engine speed 1,450 ~ 1,550 r/minRecoil starter bolt 10 Nm 1.0 m kg, 7.2 ft Ib 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 chartDo not allow foreign material to enter the crankcase Changing the Engine OIL Replacement stepsOil 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 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 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 LaterRecommended 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 AbsorbersChecking the Tires Tire Characteristics Manufacturer Size TypeMaxxis 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 timeExample Charging method using a variable voltage charger YES Charging method using a constant voltage charger Checking the Fuses Description Pocket tester YU-03112-CQuantity Adjusting the Headlight Beams Changing the Headlight Bulb 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 Hoses and Leads Removing the hoses and leads Install all of the bolts/nuts and then SpecificationsEngine Mounting Bolts 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 CoversChecking 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 Removing the camshaft, rocker Arms and valvesCamshaft 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 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 Removing the Piston Piston pin puller set YU-01304Do not use a hammer to drive the piston pin out Checking the Timing Chain Guide Measurement steps 1st step Cylinder bore C 84.500 ~ 84.510 mm 3268 ~ 3.327205 mm 0016 3rd step Checking the Piston RingsSide clearance Standard Limit Top 03 ~ 0.08 mm 13 mm Ring End gap Standard Limit ~ 0.40 mm 65 mm Ring2nd ~ 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 Removing the A.C. Magneto Flywheel puller YM-01404Disassembling the Recoil Starter 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 PulleyAssembling 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 Removing the primary Secondary sheavesPrimary and Secondary Sheaves For installation, reverse the removal Primary Sliding Sheave Disassembling the primary slidingSheave Sheave Disassembling the secondary Secondary SheaveAssembling the Secondary Removing the Primary Secondary Sheaves Sheave holder YS-01880-ADisassembling the Secondary Sheave Removing steps Weight outside diameter 30 mm 1.18 Limit 29.5 mm 1.16 Checking the Primary SheaveChecking the Secondary 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 ClutchChecking the Clutch Installing the Clutch Install Dowel pins Gasket New Clutch housing assembly Starter MOTOR, Timing Chain and OIL Filter Removing the starter motor, timingChain and oil filter OIL Pump Drive Gear ENG Separating the crankcase CrankcaseLever Removing the crankcase bearings Crankcase BearingsPump Removing the OIL Pump Drive Gear Removal stepsSeparating the Crankcase Separation steps Checking the Timing Chain and Guide Checking the OIL Strainer and OIL Delivery Pipe Checking the Bearings Checking the CrankcaseAssembling the Crankcase Installing the Shift Lever Installing the OIL Pump Drive Gear Tightening steps CRANKSHAFT/INSTALLING Removing the crankshaft and oilPump Crankshaft and Balancer OIL Pump Disassembling the oil pump Crankcase separating tool YU-01135-A Removing the CrankshaftChecking 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 Forks Do not attempt to straighten a bent guide barChecking the Shift CAM Checking the Transmission Checking the Secondary Shaft and Driven Sprocket Checking the Chain Installing the Transmission Removing the middle drive shaft 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 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 Installing the Middle Drive Shaft Measuring the Middle Gear BacklashMiddle gear lash ~ 0.3 mm 0.004 ~ 0.012 Measurement steps 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 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 Gear lash measurement tool YM-01475 Differential gear lash 10 ~ 0.50 mm 0.004 ~ 0.020 Adjusting differential gear lash Reduce shimIncrease shim Ring gear shim left and right Thickness mm Checking the Differential Gear Operation Gear assembly and drive shaft InstallingRemoving the rear axle, final drive Rear Axle Disassembling the final drive gear Gear Assembling the Final DriveDrive Roller Bearings Removing the Rear Axle Disassembling the Final Drive Gear Replacing the Final Drive Roller Bearings Positioning the Final Drive Pinion Gear and Ring Gear Final drive pinion gear shim selectionFinal drive pinion gear shim thickness a = a b 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 Ring gear thrust clearance ~ 0.2 mm 0.004 ~ 0.008 Thrust washer selection stepsThrust washer Thickness mm Ring gear stopper shim selection Ring gear stopper clearance adjustment Shim Thickness mmRing gear stopper clearance 0.30 ~ 0.60 mm 0.012 ~ 0.024 Checking the Rear Axle Checking the Drive Shaft Checking the Final Drive Gear Final gear lash measurement Measurement and Adjusting the Final Gear LashFinal 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 GearLithium-soap-based grease Sealant Quick gasket ACC-11001-05-01 Yamaha bond No.1215 Nuts Bolts Front Wheels Removing the front wheelsIs no danger of it falling over Hubs Rear Wheels Removing the rear wheels Checking the Wheel Hubs Installing the Wheel Hubs Installing the WheelsChecking the Brake Discs Brake disc maximum deflection 15 mm 0.006 Install Nuts wheel Removing the front brake pads 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 Front Brake Master Cylinder Removing the front brake masterCylinder 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 CaliperCalipers Calipers Assembling the Front Brake Disassembling the Front Brake Calipers Recommended brake component Replacement schedule Brake padsChecking 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 Installing the Rear Brake Brake shoe lining thickness limit 2.0 mm 0.08Brake drum inside diameter limit maximum 161 mm 6.34 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 Cylinder Assembly Brake SwitchHandlebar Removing the handlebar Removing the Rear Brake Switch Installing the HandlebarInstalling the Rear Brake Lever Checking the Handlebar Installing the Master Cylinder Assembly Removing the steering stem Steering StemGuide Bearing Retainer Installing the Bearing Retainer Installing the Cable GuideRemoving the Bearing Retainer Checking the Steering Stem TIE Rods and Steering Knuckles Removing the tie rods and steeringKnuckles 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 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 AbsorberNut 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 SwingarmChecking the Rear Shock Absorber Installing the Rubber Boot Checking 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 Shown in the Manual Checking a SwitchExample 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 Troubleshooting ProcedureOpen-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 Both Meet Specification Correct OUT of SpecificationC0NTINUITY 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 Starter Motor Removing the 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 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 Meets Specification OUT SpecificationOUT of 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 Step235.4 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 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 Hard Shifting Shift Lever does not MoveJumps OUT of Gear Engine Operates but Machine will not Move Overheating Poor Speed PerformancePoor Braking Effect Malfunction Unstable HandlingHeadlight Dark Bulb Burnt OUT YFM400FAR Wiring Diagram Shingai Iwata Shizuoka Japan