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Yamaha 5TE-F8197-10, LIT-11616-16-02 service manual 2 - 16

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SPEC

Tightening torques

Part to be tightened Thread size Tightening torque Remarks

Nm m·kg ft·lb

Engine bracket (front-upper) and frame M8 33 3.3 24

Engine bracket (front-lower) and frame M8 33 3.3 24

Engine bracket (front-upper) and engine M10 42 4.2 30

Engine bracket (front-lower) and engine M10 42 4.2 30

Engine and frame M10 56 5.6 40

Frame and bearing retainer (steering stem holder

bearing)

M42 40 4.0 29

Select lever assembly and frame M8 23 2.3 17

Swingarm M12 82 8.2 60

Rear shock absorber and frame M12 82 8.2 60

Final gear case and swingarm M10 63 6.3 45 LT

Final gear case and rear axle housing M10 63 6.3 46

Swingarm and rear axle housing M10 63 6.3 46

Differential gear case and frame M10 55 5.5 40

Front arm and frame M10 45 4.5 32 LS

Front shock absorber and frame M10 45 4.5 32

Front shock absorber and upper front arm M10 45 4.5 32

Steering stem, pitman arm and frame M14 130 13.0 94 LS

Steering stem holder and frame M8 23 2.3 17 Use lock

washer

Steering stem and handlebar holder M8 23 2.3 17

Pitman arm and tie-rod end M12 30 3.0 22

Tie-rod and locknut M12 40 4.0 29

Steering knuckle and upper front arm M12 30 3.0 22

Steering knuckle and lower front arm M12 30 3.0 22 LS

Steering knuckle and tie-rod M12 30 3.0 22

Fuel tank and fuel cock M6 4 0.4 2.9

Front wheel and wheel hub M10 64 6.4 46

Front axle and wheel hub M16 150 15.0 110

Steering knuckle and brake caliper M8 30 3.0 22

Front brake disc and wheel hub M8 30 3.0 22 LT

Rear wheel and rear wheel hub M10 55 5.5 40

Rear axle and nut M16 150 15.0 110

Brake drum cover and brake shoe plate M6 28 2.8 20 LT

Front brake pipe nut M10 19 1.9 13

Front brake hose union bolt M10 27 2.7 19

Bleed screw M8 6 0.6 4.3

Master cylinder and handlebar M6 7 0.7 5.1

Footrest and frame M8 16 1.6 11

MAINTENANCE SPECIFICATIONS

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)