Yamaha 5TE-F8197-10, LIT-11616-16-02 User Manual
YFM400FAR
SERVICE MANUAL
LIT-11616-16-02 5TE-F8197-10
YFM400FAR
SERVICE MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, April 2002
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-16-02
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha
dealers and will appear in future editions of this manual where applicable.
OTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the machine operator, a bystander or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
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.
12
GEN
INFO
34
SPEC
CHK
ENG
ADJ
56
COOL
78
CARB
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 0 are printed on the
top right of each page and indicate the subject
of each chapter.
General information
1
Specifications
2
Periodic checks and adjustments
3
Engine
4
Cooling system
5
Carburetion
6
Drive train
7
Chassis
8
Electrical
9
Troubleshooting
0
DRIV
90
–+
ELEC
AB
CD
EF
T
.
R
.
GH
CHAS
TRBL
SHTG
Illustrated symbols A to H are used to identify
the specifications appearing in the text.
Can be serviced with engine mounted
A
Filling fluid
B
Lubricant
C
Special tool
D
Torque
E
Wear limit, clearance
F
Engine speed
G
, V, A
Ω
H
IJK
LS
G
M
M
New
E
LMN
B
OP
LT
Illustrated symbols I to N in the exploded
diagrams indicate the types of lubricants and
lubrication points.
Apply engine oil
I
Apply gear oil
J
Apply molybdenum disulfide oil
K
Apply wheel bearing grease
L
Apply lithium-soap-based grease
M
Apply molybdenum disulfide grease
N
Illustrated symbols O to P in the exploded
diagrams indicate where to apply a locking
agent O and when to install a new part P.
®
Apply the locking agent (LOCTITE
O
Replace
P
)
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
GEN
INFO
SPEC
CHK
ADJ
ENG
COOL
1
2
3
4
5
CARBURETION
DRIVE TRAIN
CHASSIS
ELECTRICAL
TROUBLESHOOTING
CARB
DRIV
CHAS
– +
ELEC
TRBL
SHTG
6
7
8
9
10
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER ................................................. 1-1
MODEL LABEL ...................................................................................... 1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES ............................... 1-2
REPLACEMENT PARTS ....................................................................... 1-2
GASKETS, OIL SEALS AND O-RINGS ................................................ 1-2
LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-3
BEARINGS AND OIL SEALS ................................................................ 1-3
CIRCLIPS ..............................................................................................1-3
CHECKING OF CONNECTIONS
SPECIAL TOOLS
..........................................................................................1-5
........................................................................1-1
.......................................................................1-2
.................................................................. 1-4
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE .................................................................................................2-4
CHASSIS ............................................................................................. 2-14
ELECTRICAL ......................................................................................2-18
HOW TO USE THE CONVERSION TABLE
GENERAL TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE ...............................................................................................2-21
COOLANT FLOW DIAGRAMS
OIL FLOW DIAGRAMS
CABLE ROUTING
..............................................................................2-24
.......................................................................................2-27
......................................................................2-1
............................................................. 2-4
............................................... 2-20
................................................... 2-20
.................................. 2-21
................................................................... 2-22
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
SEAT, CARRIERS, FENDERS AND FUEL TANK
SEAT AND SIDE PANELS .................................................................... 3-3
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ............. 3-4
REAR CARRIER AND REAR FENDER ................................................ 3-6
FUEL TANK ........................................................................................... 3-8
FOOTREST BOARDS
ENGINE
.......................................................................................................3-10
ADJUSTING THE VALVE CLEARANCE ............................................ 3-10
ADJUSTING THE IDLING SPEED ......................................................3-13
ADJUSTING THE THROTTLE LEVER FREE PLAY .......................... 3-14
ADJUSTING THE SPEED LIMITER .................................................... 3-16
ADJUSTING THE STARTER CABLE .................................................3-17
CHECKING THE SPARK PLUG ......................................................... 3-19
CHECKING THE IGNITION TIMING ................................................... 3-20
MEASURING THE COMPRESSION PRESSURE .............................. 3-21
CHECKING THE ENGINE OIL LEVEL ................................................ 3-23
CHANGING THE ENGINE OIL ...........................................................3-24
CLEANING THE AIR FILTER .............................................................. 3-26
CHECKING THE COOLANT LEVEL ...................................................3-29
CHANGING THE COOLANT ............................................................... 3-30
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ..... 3-33
CHECKING THE V-BELT ....................................................................3-33
CLEANING THE SPARK ARRESTER ................................................ 3-34
...........................................................................................3-1
................................................ 3-1
....................................... 3-3
..................................................................................3-9
CHASSIS
ADJUSTING THE REAR BRAKE ........................................................ 3-36
CHECKING THE FRONT BRAKE FLUID LEVEL ............................... 3-38
CHECKING THE FRONT BRAKE PADS ............................................ 3-39
CHECKING THE REAR BRAKE SHOES ............................................ 3-39
CHECKING THE BRAKE HOSES ....................................................... 3-40
BLEEDING THE HYDRAULIC BRAKE SYSTEM ............................... 3-41
ADJUSTING THE SELECT LEVER CONTROL CABLE AND
ADJUSTING THE REAR BRAKE LIGHT SWITCH ............................. 3-43
CHECKING THE FINAL GEAR OIL LEVEL ........................................ 3-44
CHANGING THE FINAL GEAR OIL ....................................................3-45
CHANGING THE DIFFERENTIAL GEAR OIL .................................... 3-46
....................................................................................................3-36
SHIFT ROD ..................................................................................... 3-42
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ...... 3-46
CHECKING THE STEERING SYSTEM .............................................. 3-47
ADJUSTING THE TOE-IN ...................................................................3-47
ADJUSTING THE FRONT SHOCK ABSORBERS ............................. 3-49
ADJUSTING THE REAR SHOCK ABSORBER .................................. 3-49
CHECKING THE TIRES ......................................................................3-49
CHECKING THE WHEELS ................................................................. 3-52
CHECKING AND LUBRICATING THE CABLES ................................3-52
LUBRICATING THE LEVERS, PEDAL, ETC. ..................................... 3-53
ELECTRICAL .............................................................................................. 3-54
CHECKING THE BATTERY ................................................................3-54
CHECKING THE FUSES .................................................................... 3-59
ADJUSTING THE HEADLIGHT BEAMS ............................................. 3-61
CHANGING THE HEADLIGHT BULB ................................................. 3-61
CHAPTER 4.
ENGINE
ENGINE REMOVAL ...................................................................................... 4-1
AIR DUCTS, MUFFLER AND EXHAUST PIPE .................................... 4-1
SELECT LEVER UNIT AND COOLANT RESERVOIR ......................... 4-3
HOSES AND LEADS ............................................................................. 4-4
ENGINE MOUNTING BOLTS ...............................................................4-5
INSTALLING THE ENGINE ................................................................... 4-7
CYLINDER HEAD .........................................................................................4-8
REMOVING THE CYLINDER HEAD ................................................... 4-10
CHECKING THE TAPPET COVERS .................................................. 4-11
CHECKING THE TIMING CHAIN TENSIONER .................................. 4-11
CHECKING THE CAMSHAFT SPROCKET ........................................4-11
CHECKING THE CYLINDER HEAD ................................................... 4-12
INSTALLING THE CYLINDER HEAD ................................................. 4-13
CAMSHAFT, ROCKER ARMS AND VALVES ........................................... 4-16
REMOVING THE CAMSHAFT AND ROCKER ARMS ........................ 4-18
REMOVING THE VALVES AND VALVE SPRINGS ........................... 4-18
CHECKING THE CAMSHAFT ............................................................. 4-19
CHECKING THE ROCKER ARMS AND CAMSHAFT ........................ 4-19
CHECKING THE VALVES AND VALVE SPRINGS ............................ 4-21
INSTALLING THE VALVES AND VALVE SPRINGS .......................... 4-25
INSTALLING THE CAMSHAFT AND ROCKER ARMS ...................... 4-26
CYLINDER AND PISTON ........................................................................... 4-27
REMOVING THE PISTON ..................................................................4-28
CHECKING THE TIMING CHAIN GUIDE ........................................... 4-28
CHECKING THE CYLINDER AND PISTON ....................................... 4-28
CHECKING THE PISTON RINGS ....................................................... 4-30
CHECKING THE PISTON PIN ............................................................ 4-31
INSTALLING THE PISTON ................................................................. 4-32
INSTALLING THE CYLINDER ............................................................ 4-33
RECOIL STARTER AND A.C. MAGNETO ................................................ 4-34
REMOVING THE A.C. MAGNETO ...................................................... 4-37
DISASSEMBLING THE RECOIL STARTER ....................................... 4-37
CHECKING THE A.C. MAGNETO ...................................................... 4-37
CHECKING THE STARTER CLUTCH ................................................ 4-38
CHECKING THE STARTER PULLEY .................................................4-39
CHECKING THE RECOIL STARTER ................................................. 4-39
ASSEMBLING THE RECOIL STARTER .............................................4-39
INSTALLING THE A.C. MAGNETO .................................................... 4-40
PRIMARY AND SECONDARY SHEAVES ................................................. 4-42
PRIMARY SLIDING SHEAVE ............................................................. 4-44
SECONDARY SHEAVE ...................................................................... 4-45
REMOVING THE PRIMARY AND SECONDARY SHEAVES ............. 4-46
DISASSEMBLING THE SECONDARY SHEAVE ................................ 4-46
CHECKING THE PRIMARY SHEAVE ................................................4-47
CHECKING THE SECONDARY SHEAVE .......................................... 4-47
ASSEMBLING THE PRIMARY SHEAVE ............................................ 4-48
ASSEMBLING THE SECONDARY SHEAVE ...................................... 4-48
INSTALLING THE PRIMARY AND SECONDARY SHEAVES ............ 4-50
CLUTCH ......................................................................................................4-51
REMOVING THE CLUTCH ................................................................. 4-53
CHECKING THE CLUTCH ..................................................................4-53
INSTALLING THE CLUTCH ................................................................4-54
CRANKCASE ..............................................................................................4-56
STARTER MOTOR, TIMING CHAIN AND OIL FILTER ...................... 4-56
CRANKCASE ......................................................................................4-58
CRANKCASE BEARINGS ................................................................... 4-59
REMOVING THE OIL PUMP DRIVE GEAR .......................................4-60
SEPARATING THE CRANKCASE ...................................................... 4-60
CHECKING THE TIMING CHAIN AND GUIDE ................................... 4-61
CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE ............ 4-61
CHECKING THE CRANKCASE .......................................................... 4-62
CHECKING THE BEARINGS .............................................................. 4-62
ASSEMBLING THE CRANKCASE ...................................................... 4-62
INSTALLING THE SHIFT LEVER ....................................................... 4-63
INSTALLING THE OIL PUMP DRIVE GEAR ...................................... 4-64
CRANKSHAFT AND OIL PUMP ................................................................ 4-65
OIL PUMP ........................................................................................... 4-66
REMOVING THE CRANKSHAFT .......................................................4-67
CHECKING THE OIL PUMP ............................................................... 4-67
CHECKING THE CRANKSHAFT ........................................................ 4-68
INSTALLING THE CRANKSHAFT AND BALANCER ......................... 4-69
TRANSMISSION .........................................................................................4-70
CHECKING THE SHIFT FORKS ......................................................... 4-72
CHECKING THE SHIFT CAM ............................................................. 4-72
CHECKING THE TRANSMISSION ..................................................... 4-72
CHECKING THE SECONDARY SHAFT AND
DRIVEN SPROCKET ...................................................................... 4-73
CHECKING THE CHAIN ..................................................................... 4-73
INSTALLING THE TRANSMISSION ................................................... 4-74
MIDDLE GEAR ...........................................................................................4-75
MIDDLE DRIVE SHAFT ...................................................................... 4-75
MIDDLE DRIVEN SHAFT .................................................................... 4-76
REMOVING THE MIDDLE DRIVE SHAFT .........................................4-78
REMOVING THE MIDDLE DRIVEN SHAFT .......................................4-78
CHECKING THE PINION GEARS ......................................................4-80
SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS ....... 4-81
INSTALLING THE MIDDLE DRIVEN SHAFT ..................................... 4-84
INSTALLING THE MIDDLE DRIVE SHAFT ........................................ 4-86
MEASURING THE MIDDLE GEAR BACKLASH ................................. 4-86
CHAPTER 5.
COOLING SYSTEM
RADIATOR .................................................................................................... 5-1
CHECKING THE RADIATOR ................................................................5-3
INSTALLING THE RADIATOR ..............................................................5-4
THERMOSTAT ..............................................................................................5-5
CHECKING THE THERMOSTAT .......................................................... 5-6
INSTALLING THE THERMOSTAT ........................................................ 5-6
WATER PUMP ..............................................................................................5-7
DISASSEMBLING THE WATER PUMP ................................................ 5-9
CHECKING THE WATER PUMP .......................................................... 5-9
ASSEMBLING THE WATER PUMP .................................................... 5-10
CHAPTER 6.
CARBURETION
CARBURETOR
DISASSEMBLING THE CARBURETOR ...............................................6-4
CHECKING THE CARBURETOR ......................................................... 6-4
ASSEMBLING THE CARBURETOR .....................................................6-6
ADJUSTING THE FUEL LEVEL ............................................................ 6-7
.............................................................................................6-1
CHAPTER 7.
DRIVE TRAIN
TROUBLESHOOTING
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY ......................... 7-9
CHECKING THE CONSTANT VELOCITY JOINTS .............................. 7-9
CHECKING THE DIFFERENTIAL GEAR ............................................ 7-10
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS .......... 7-10
ASSEMBLING THE DIFFERENTIAL GEAR ....................................... 7-11
MEASURING AND ADJUSTING THE DIFFERENTIAL
GEAR LASH .................................................................................... 7-12
CHECKING THE DIFFERENTIAL GEAR OPERATION ..................... 7-14
..................................................................................7-1
..... 7-4
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
REMOVING THE REAR AXLE ............................................................ 7-18
DISASSEMBLING THE FINAL DRIVE GEAR ..................................... 7-18
REPLACING THE FINAL DRIVE ROLLER BEARINGS ..................... 7-19
POSITIONING THE FINAL DRIVE PINION GEAR AND
RING GEAR .....................................................................................7-20
CHECKING THE REAR AXLE ............................................................ 7-24
CHECKING THE DRIVE SHAFT ......................................................... 7-25
CHECKING THE FINAL DRIVE GEAR ............................................... 7-25
MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH .......... 7-26
ASSEMBLING THE FINAL DRIVE GEAR ........................................... 7-28
INSTALLING THE FINAL DRIVE GEAR ............................................. 7-28
........................... 7-15
CHAPTER 8.
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS .................................................................................. 8-1
REAR WHEELS ....................................................................................8-2
CHECKING THE WHEELS ................................................................... 8-3
CHECKING THE WHEEL HUBS ........................................................... 8-3
CHECKING THE BRAKE DISCS .......................................................... 8-4
INSTALLING THE WHEEL HUBS ......................................................... 8-4
INSTALLING THE WHEELS ................................................................. 8-4
FRONT BRAKE
FRONT BRAKE PADS .......................................................................... 8-6
REPLACING THE FRONT BRAKE PADS ............................................ 8-7
FRONT BRAKE MASTER CYLINDER .................................................. 8-9
CHECKING THE MASTER CYLINDER .............................................. 8-11
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...............8-11
INSTALLING THE FRONT BRAKE MASTER CYLINDER .................. 8-12
FRONT BRAKE CALIPER ................................................................... 8-14
DISASSEMBLING THE FRONT BRAKE CALIPERS .......................... 8-16
CHECKING THE FRONT BRAKE CALIPERS .................................... 8-16
ASSEMBLING THE FRONT BRAKE CALIPERS ................................ 8-17
INSTALLING THE FRONT BRAKE CALIPERS .................................. 8-17
............................................................................................8-6
......................................................................8-1
REAR BRAKE
REMOVING THE REAR BRAKE ......................................................... 8-23
CHECKING THE REAR BRAKE ......................................................... 8-24
INSTALLING THE REAR BRAKE ....................................................... 8-25
STEERING SYSTEM
HANDLEBAR ....................................................................................... 8-28
REMOVING THE REAR BRAKE SWITCH .........................................8-29
CHECKING THE HANDLEBAR .......................................................... 8-29
INSTALLING THE HANDLEBAR ........................................................ 8-29
INSTALLING THE REAR BRAKE LEVER .......................................... 8-29
INSTALLING THE MASTER CYLINDER ASSEMBLY ........................ 8-30
STEERING STEM ............................................................................... 8-31
REMOVING THE BEARING RETAINER ............................................8-33
CHECKING THE STEERING STEM ................................................... 8-33
INSTALLING THE BEARING RETAINER ........................................... 8-33
INSTALLING THE CABLE GUIDE ...................................................... 8-33
TIE RODS AND STEERING KNUCKLES ........................................... 8-34
REMOVING THE STEERING KNUCKLES ......................................... 8-36
CHECKING THE TIE RODS ............................................................... 8-36
CHECKING THE STEERING KNUCKLES .......................................... 8-36
INSTALLING THE TIE RODS ............................................................. 8-39
.............................................................................................8-19
..................................................................................8-28
FRONT ARMS AND FRONT SHOCK ABSORBERS ................................ 8-40
REMOVING THE FRONT ARMS ........................................................ 8-42
CHECKING THE FRONT ARMS ......................................................... 8-42
CHECKING THE FRONT SHOCK ABSORBER ................................. 8-44
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER .......................................................... 8-45
REAR SHOCK ABSORBER AND SWINGARM ......................................... 8-46
REMOVING THE SWINGARM ............................................................ 8-48
CHECKING THE REAR SHOCK ABSORBER .................................... 8-48
CHECKING THE SWINGARM ............................................................ 8-49
CHECKING THE RUBBER BOOT ...................................................... 8-49
INSTALLING THE RUBBER BOOT .................................................... 8-49
INSTALLING THE REAR AXLE HOUSING ........................................8-50
CHAPTER 9.
ELECTRICAL
ELECTRICAL COMPONENTS ..................................................................... 9-1
CHECKING THE SWITCHES .......................................................................9-2
CHECKING A SWITCH ......................................................................... 9-2
CHECKING A SWITCH SHOWN IN THE MANUAL .............................9-2
CHECKING THE SWITCH CONTINUITY ............................................. 9-4
CHECKING THE BULBS AND BULB SOCKETS ........................................ 9-6
TYPES OF BULBS ................................................................................ 9-6
CHECKING THE CONDITION OF THE BULBS ................................... 9-6
CHECKING THE CONDITION OF THE BULB SOCKETS ................... 9-8
IGNITION SYSTEM ....................................................................................... 9-9
CIRCUIT DIAGRAM .............................................................................. 9-9
TROUBLESHOOTING ........................................................................9-10
ELECTRIC STARTING SYSTEM ...............................................................9-15
CIRCUIT DIAGRAM ............................................................................ 9-15
TROUBLESHOOTING ........................................................................9-16
STARTER MOTOR .............................................................................9-19
CHECKING THE STARTER MOTOR ................................................. 9-20
ASSEMBLING THE STARTER MOTOR .............................................9-21
CHARGING SYSTEM ................................................................................. 9-22
CIRCUIT DIAGRAM ............................................................................ 9-22
TROUBLESHOOTING ........................................................................9-23
LIGHTING SYSTEM .................................................................................... 9-25
CIRCUIT DIAGRAM ............................................................................ 9-25
TROUBLESHOOTING ........................................................................ 9-26
CHECKING THE LIGHTING SYSTEM ................................................ 9-28
SIGNAL SYSTEM ....................................................................................... 9-32
CIRCUIT DIAGRAM ............................................................................ 9-32
TROUBLESHOOTING ........................................................................ 9-34
CHECKING THE SIGNAL SYSTEM ................................................... 9-36
COOLING SYSTEM .................................................................................... 9-43
CIRCUIT DIAGRAM ............................................................................ 9-43
TROUBLESHOOTING ....................................................................... 9-44
2WD/4WD SELECTING SYSTEM .............................................................. 9-48
CIRCUIT DIAGRAM ............................................................................ 9-48
TROUBLESHOOTING ........................................................................ 9-49
CHAPTER 10.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ................................................... 10-1
FUEL SYSTEM .................................................................................... 10-1
ELECTRICAL SYSTEM ....................................................................... 10-1
COMPRESSION SYSTEM .................................................................. 10-2
POOR IDLE SPEED PERFORMANCE ...................................................... 10-2
POOR IDLE SPEED PERFORMANCE ............................................... 10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ............................. 10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ..................... 10-2
FAULTY DRIVE TRAIN .............................................................................. 10-3
FAULTY GEAR SHIFTING ......................................................................... 10-4
HARD SHIFTING ................................................................................. 10-4
SHIFT LEVER DOES NOT MOVE ...................................................... 10-4
JUMPS OUT OF GEAR ....................................................................... 10-4
FAULTY CLUTCH PERFORMANCE .........................................................10-4
ENGINE OPERATES BUT MACHINE WILL NOT MOVE ................... 10-4
CLUTCH SLIPPING ............................................................................ 10-4
POOR STARTING PERFORMANCE .................................................. 10-4
POOR SPEED PERFORMANCE ........................................................ 10-5
OVERHEATING .......................................................................................... 10-5
OVERHEATING ..................................................................................10-5
FAULTY BRAKE .........................................................................................10-5
POOR BRAKING EFFECT ..................................................................10-5
SHOCK ABSORBER MALFUNCTION ....................................................... 10-6
MALFUNCTION ...................................................................................10-6
UNSTABLE HANDLING ............................................................................. 10-6
UNSTABLE HANDLING ...................................................................... 10-6
LIGHTING SYSTEM ....................................................................................10-6
HEADLIGHT DARK ............................................................................. 10-6
BULB BURNT OUT ............................................................................. 10-6
MACHINE IDENTIFICATION
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the left side of the frame.
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
GEN
INFO
1 - 1
IMPORTANT INFORMATION
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1.Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2.Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3.When disassembling the machine, always
keep mated parts together. This includes
gears, cylinder, piston and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4.During machine disassembly, clean all parts
and place them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
5.Keep all parts away from any source of fire.
GEN
INFO
1
EB101010
REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all
replacements. Use oil and grease
recommended by Yamaha for all lubrication
jobs. Other brands may be similar in function
and appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1.Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2.Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1 - 2
IMPORTANT INFORMATION
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1.Replace all lock washers/plates 1 and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1.Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.
Oil seal
1
GEN
INFO
CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
Bearing
1
EB101050
CIRCLIPS
1.Check all circlips carefully before
reassembly. Always replace piston pin clips
after one use. Replace distorted circlips.
When installing a circlip 1, make sure that
the sharp-edged corner 2 is positioned
opposite the thrust 3 it receives. See
sectional view.
Shaft
4
1 - 3
CHECKING OF CONNECTIONS
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust,
moisture, etc.
1.Disconnect:
●
Connector
2.Check:
●
Connector
Moisture → Dry each terminal with an air
blower.
Stains/rust → Connect and disconnect the
terminals several times.
3.Check:
●
Connector leads
Looseness → Bend up the pin 1 and
connect the terminals.
GEN
INFO
4.Connect:
●
Connector terminals
OTE:
The two terminals “click” together.
5.Check:
●
Continuity (using a pocket tester)
OTE:
●
If there is no continuity, clean the terminals.
●
When checking the wire harness be sure to
perform steps 1 to 3.
●
As a quick remedy, use a contact revitalizer
available at most part stores.
●
Check the connector with a pocket tester as
shown.
1 - 4
GEN
SPECIAL TOOLS
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US and CDN
P/N. 90890-
Tool No. Tool name/How to use Illustration
INFO
Bolt
90890-01083
Weight
90890-01084
Set
YU-01083-A
90890-01135
YU-01135-A
90890-01225
YM-01225-A
90890-04017
YM-04017
Slide hammer bolt (M6)/weight/set
These tools are used to remove the
rocker arm shafts.
Crankcase separating tool
This tool is used to separate the
crankcase.
Valve guide remover (7.0 mm)
This tool is needed to remove and
install the valve guides.
Valve guide installer (7.0 mm)
This tool is needed to install the valve
guides.
Valve guide reamer (7.0 mm)
90890-01227
YM-01227
90890-01235
YU-01235
90890-04088
Bolt
90890-01275
This tool is needed to rebore the new
valve guides.
Rotor holding tool
This tool is needed to hold the starter
pulley when removing/installing the
starter pulley bolt or camshaft
sprocket bolt.
Buffer boss installer set
Crankshaft installer bolt
These tools are used to install the
crankshaft.
1 - 5
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Crankshaft installer set
YU-90050
These tools are used to install the
crankshaft.
INFO
Adapter
YM-33279
Spacer
90890-04060
YM-90070-A
90890-01304
YU-01304
90890-01311
YU-08035
90890-01312
YM-01312-A
Adapter #11
Spacer (crankshaft)
These tools are used to install the
crankshaft.
Piston pin puller set
This tool is used to remove the piston
pin.
Tappet adjusting tool
This tool is necessary for adjusting
the valve clearance.
Fuel level gauge
This gauge is used to measure the
fuel level in the float chamber.
Radiator cap tester
90890-01325
YU-24460-01
90890-01352
YU-33984
90890-01348
YM-01348
90890-04134
YM-04134
This tool is used to check the cooling
systems.
Adapter
This tool is used to check the cooling
systems.
Locknut wrench
This tool is needed when removing or
installing the secondary sheave
spring.
Sheave spring compressor
This tool is needed when removing or
installing the secondary sheave
spring.
1 - 6
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Sheave fixed block
INFO
90890-04135
YM-04135
90890-01404
YM-01404
90890-01327
YM-01327
90890-01426
YU-38411
90890-01430
YM-38404
This tool is needed when removing or
installing the secondary sheave
spring.
Flywheel puller
These tools are needed to remove
the rotor.
Damper rod holder (30 mm)
This tool is needed to loosen and
tighten the steering stem bearing
retainers.
Oil filter wrench
This tool is needed to loosen or
tighten the oil filter cartridge.
Ring nut wrench
This tool is needed to removing and
installing the middle driven shaft
bearing retainers.
90890-01467
YM-01467
90890-01475
YM-01475
90890-01474
YM-01474
YM-01477
90890-01701
YS-01880-A
Gear lash measurement tool
This tool is used to measure the gear
lash.
Ball joint remover/installer set
This tool is used to remove and install
the ball joints.
Ball joint remover/installer attachment
set
This tool is used to remove and install
the ball joints.
Sheave holder
This tool is needed to hold the
primary sheave when removing or
installing the sheave bolts.
1 - 7
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
INFO
Compression gauge
90890-03081
YU-33223
Adapter
90890-04082
YU-33223-3
90890-03112
YU-03112-C
90890-03113
YU-8036-B
Compression gauge
Adapter
These tools are needed to measure
engine compression.
Pocket tester
This instrument is needed for
checking the electrical system.
Engine tachometer
This tool is needed for observing
engine rpm.
Inductive self-powered tachometer
This tool is needed for observing
engine rpm.
Timing light
90890-03141
YM-33277-A
90890-04019
YM-04019
Middle driven shaft
bearing driver
90890-04058
YM-04058-1
Mechanical seal installer
90890-04078
YM-33221
90890-04050
YM-04050
90890-04062
YM-04062
This tool is necessary for checking
ignition timing.
Valve spring compressor
This tool is needed to remove and
install the valve assemblies.
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the
water pump seals.
Bearing retainer wrench
This tool is needed when removing or
installing the final drive shaft bearing
retainers.
Universal joint holder
This tool is needed when removing or
installing the universal joint yoke nuts.
1 - 8
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Clutch holding tool
INFO
90890-04086
YM-91042
90890-04128
YM-04128
90890-04129
YM-04129
90890-06754
This tool is needed to hold the clutch
carrier when removing or installing
the carrier nut.
Bearing retainer wrench
This tool is needed when removing or
installing the middle driven pinion
gear bearing retainers.
Pinion gear fix clamp
This tool is used to hold the shift cam.
Ignition checker
This instrument is necessary for
checking the ignition system
components.
Dynamic spark tester
YM-34487
Bond
90890-85505
Sealant
ACC-11001-05-01
This instrument is necessary for
checking the ignition system
components.
Yamaha bond No. 1215
Sealant (Quick Gasket
This sealant (bond) is used on
crankcase mating surfaces, etc.
®
)
1 - 9
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5TE1, 5TE5
Dimensions:
Overall length 1,984 mm (78.1 in)
Overall width 1,085 mm (42.7 in)
Overall height 1,120 mm (44.1 in)
Seat height 827 mm (32.6 in)
Wheelbase 1,233 mm (48.5 in)
Minimum ground clearance 245 mm (9.7 in)
Minimum turning radius 3,000 mm (118.1 in)
Basic weight:
With oil and full fuel tank 265 kg (584 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 401 cm
Bore × stroke 84.5 × 71.5 mm (3.33 × 2.81 in)
Compression ratio 10.5 : 1
Standard compression pressure (at sea level) 1,400 kPa (14.0 kg/cm
Starting system Electric and recoil starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
3
2
SPEC
2
, 203 psi) at 750 r/min
API service SE, SF, SG type or higher
Final gear oil SAE 80API “GL-4” Hypoid Gear Oil
Differential gear oil SAE 80API “GL-4” Hypoid Gear Oil
Oil capacity:
Engine oil
Periodic oil change 2.3 L (2.0 Imp qt, 2.4 US qt)
With oil filter replacement 2.4 L (2.1 Imp qt, 2.5 US qt)
Total amount 2.6 L (2.3 Imp qt, 2.7 US qt)
Final gear case oil
Periodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt)
Total amount 0.25 L (0.22 Imp qt, 0.26 US qt)
2 - 1
GENERAL SPECIFICATIONS
Item Standard
Differential gear case oil
Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt)
Total amount 0.40 L (0.35 Imp qt, 0.42 US qt)
Radiator capacity (including all routes) 1.32 L (1.16 Imp qt, 1.40 US qt)
Air filter: Wet type element
Fuel:
Type Unleaded fuel
Fuel tank capacity 15 L (3.3 Imp gal, 3.9 US gal)
Fuel reserve amount 4.5 L (0.99 Imp gal, 1.19 US gal)
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DR8EA/NGK
Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type: Wet, centrifugal automatic
Transmission:
Primary reduction system V-belt
Secondary reduction system Spur gear
Secondary reduction ratio 39/24 × 24/18 × 33/9 (7.944)
Transmission type V-belt automatic
Operation Left hand operation
Single speed automatic 2.55 ~ 0.75 : 1
Sub transmission ratio 38/23 (1.652)
Reverse gear 29/17 (1.706)
Chassis:
Frame type Steel tube frame
Caster angle 4°
Camber angle 1°
Kingpin angle 11°
Kingpin offset 0 mm (0 in)
Trail 21 mm (0.83 in)
Tread (STD) front 850 mm (33.46 in)
rear 825 mm (32.48 in)
Toe-in 0 ~ 10 mm (0 ~ 0.39 in)
Tires:
Type Tubeless
Size front AT25 × 8–12
rear AT25 × 10–12
Manufacturer front MAXXIS
rear MAXXIS
Type front M911Y
rear M912Y
SPEC
2 - 2
GENERAL SPECIFICATIONS
Item Standard
Tire pressure (cold tire):
Maximum load* 210 kg (463 lb)
Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm
rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm
*Load in total weight of rider accessories
Brakes:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left hand and right foot operation
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (monocross)
Shock absorbers:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel:
Front wheel travel 160 mm (6.30 in)
Rear wheel travel 180 mm (7.09 in)
Electrical:
Ignition system D.C. C.D.I.
Generator system A.C. magneto
Battery type YTX14AH
Battery capacity 12 V 12 Ah
Headlight type: Halogen bulb
Bulb wattage × quantity:
Headlight 12 V 30 W/30 W × 2
Tail/brake light 12 V 5 W/21 W
Meter light 14 V 3 W × 1
Indicator lights
Neutral 12 V 1.7 W × 1
Reverse 12 V 1.7 W × 1
Coolant temperature 12 V 1.7 W × 1
Four-wheel drive 14 V 1.7 W × 1
SPEC
2
, 3.2 ~ 4.0 psi)
2
, 3.2 ~ 4.0 psi)
2 - 3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.03 mm
(0.0012 in)
Cylinder:
Bore size 84.500 ~ 84.510 mm
(3.3268 ~ 3.3272 in)
Taper limit ---- 0.05 mm
Out of round limit ---- 0.01 mm
Camshaft:
Drive method Chain drive (left) ----
Cam dimensions
84.600 mm
(3.3307 in)
(0.0016 in)
(0.0004 in)
A
B
Intake “A” 40.62 ~ 40.72 mm
(1.5992 ~ 1.6031 in)
“B” 32.18 ~ 32.28 mm
(1.2669 ~ 1.2709 in)
Exhaust “A” 40.62 ~ 40.72 mm
(1.5992 ~ 1.6031 in)
“B” 32.18 ~ 32.28 mm
(1.2669 ~ 1.2709 in)
Camshaft runout limit ---- 0.03 mm
40.52 mm
(1.5953 in)
32.08 mm
(1.2630 in)
40.52 mm
(1.5953 in)
32.08 mm
(1.2630 in)
(0.0012 in)
2 - 4
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard Limit
Cam chain:
Cam chain type/No. of links DID SCR-0409 SDH/116 ----
Cam chain adjustment method Automatic ---Rocker arm/rocker arm shaft:
Bearing inside diameter 12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
Shaft outside diameter 11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
Arm-to-shaft clearance 0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
Valves, valve seats, valve guides:
Valve clearance (cold) IN 0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
EX 0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
Valve dimensions
12.078 mm
(0.4755 in)
11.951 mm
(0.4705 in)
0.080 mm
(0.0031 in)
----
----
A
Head Diameter
Face Width
B
Seat Width
C
Margin Thickness
“A” head diameter IN 39.9 ~ 40.1 mm
(1.5708 ~ 1.5787 in)
EX 33.9 ~ 34.1 mm
(1.3346 ~ 1.3425 in)
“B” face width IN 2.26 mm (0.0890 in) ----
EX 2.26 mm (0.0890 in) ----
“C” seat width IN 1.2 ~ 1.4 mm
(0.0472 ~ 0.0551 in)
EX 1.2 ~ 1.4 mm
(0.0472 ~ 0.0551 in)
“D” margin thickness IN 1.0 ~ 1.4 mm
(0.0394 ~ 0.0551 in)
EX 0.8 ~ 1.2 mm
(0.0315 ~ 0.0472 in)
Stem outside diameter IN 6.975 ~ 6.990 mm
(0.2746 ~ 0.2752 in)
EX 6.955 ~ 6.970 mm
(0.2738 ~ 0.2744 in)
Guide inside diameter IN 7.000 ~ 7.012 mm
(0.2756 ~ 0.2761 in)
EX 7.000 ~ 7.012 mm
(0.2756 ~ 0.2761 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
EX 0.030 ~ 0.057 mm
(0.0012 ~ 0.0022 in)
D
----
----
1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)
----
----
6.950 mm
(0.2736 in)
6.915 mm
(0.2722 in)
7.030 mm
(0.2768 in)
7.030 mm
(0.2768 in)
0.080 mm
(0.0031 in)
0.100 mm
(0.0039 in)
2 - 5
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