Yamaha YFM400FW User Manual

2000

YFM40FPM YFM400FW

(

)

4GB-AE4

SUPPLEMENTARY SERVICE MANUAL



FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM40FPM/YFM400FW(M) 2000. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

YFM400FW ’93 SERVICE MANUAL: 4GB-ME1

YFM400FW ’93 SUPPLEMENTARY SERVICE MANUAL: 4GB-AE1

YFM400FW(H) ’96 SUPPLEMENTARY SERVICE MANUAL: 4GB-AE2

YFM40FPM/YFM400FW(M) 2000

SUPPLEMENTARY SERVICE MANUAL

1999 by Yamaha Motor Co., Ltd.

1st Edition, December 1999

or unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTICE

This manual was written by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so persons using this book to perform maintenance and repairs on Yamaha machines should have a basic understanding of the mechanical concepts and the procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to the machine may render it unfit to use and/or unsafe.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

NOTE:

Designs and specifications are subject to change without notice.

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

TE:

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.

”.

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 2nd title

: This is a chapter with its symbol on the upper right of each page.

: This title appears on the upper of each page on the left of the chapter sym-

bol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title

: This is a final title.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure 4 is placed between a line of asterisks “ cedure preceded by “

●

” with each pro-

IMPORTANT FEATURES

Data and a special tool are framed in a box preceded by a relevant symbol

●

An encircled numeral alignment mark

●

A condition of a faulty component will precede an arrow symbol

indicates a part name, and an encircled alphabetical letter data or an

, the others being indicated by an alphabetical letter in a box

and the course of action will

follow it.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

GEN

SPEC

INFO

INSP

ENG

ADJ

CARB

CHAS

DRIV

–+

ELEC

TRBL

SHTG

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols thumb tabs to indicate the chapter’s number and content.

General information

Specifications

Periodic inspections and adjustments

Engine overhaul

Carburetion

Drive train

Chassis

Electrical

Troubleshooting

Illustrated symbols the specifications appearing in the text.

Filling fluid

Lubricant

Special tool

Tightening

Wear limit, clearance

Engine speed

, V, A

Ω

are designed as

are used to identify

GHI

JKL

M N

New

Illustrated symbols

in the exploded diagrams indicate grade of lubricant and location of lubrication point.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap base grease

L Apply molybdenum disulfide grease M Apply the locking agent (LOCTITE®) N Use new one

CONTENTS

GENERAL INFORMATION ..............................................................................1

MACHINE IDENTIFICATION .................................................................... 1

VEHICLE IDENTIFICATION NUMBER................................................. 1

MODEL LABEL.....................................................................................1

SPECIFICATIONS

GENERAL SPECIFICATIONS..................................................................2

MAINTENANCE SPECIFICATIONS ......................................................... 4

ENGINE ................................................................................................ 4

CHASSIS .............................................................................................. 5

ELECTRICAL........................................................................................6

CABLE ROUTING.....................................................................................8

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION.....................................................................................15

PERIODIC MAINTENANCE/LUBRICATION .......................................... 15

SEAT, CARRIERS, FENDERS AND FUEL TANK..................................17

REMOVAL........................................................................................... 17

INSTALLATION................................................................................... 20

ENGINE................................................................................................... 22

STARTER LEVER FREE PLAY ADJUSTMENT................................. 22

CHASSIS................................................................................................. 23

FRONT BRAKE PAD INSPECTION...................................................23

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)..............................23

REAR SHOCK ABSORBER ADJUSTMENT......................................24

TIRE INSPECTION............................................................................. 25

ELECTRICAL..........................................................................................27

BATTERY INSPECTION..................................................................... 27

FUSE INSPECTION............................................................................ 32

............................................................................................2

.........................................15

ENGINE OVERHAUL

ENGINE ASSEMBLY AND ADJUSTMENT ............................................34

VALVE, CAMSHAFT AND ROCKER ARM.........................................34

.....................................................................................34

CHASSIS ........................................................................................................35

FRONT AND REAR WHEELS................................................................35

REMOVAL........................................................................................... 36

FRONT BRAKE.......................................................................................38

BRAKE PAD REPLACEMENT............................................................ 39

CALIPER DISASSEMBLY .................................................................. 41

MASTER CYLINDER DISASSEMBLY................................................ 42

INSPECTION AND REPAIR...............................................................43

CALIPER ASSEMBLY ........................................................................ 46

MASTER CYLINDER ASSEMBLY...................................................... 49

FRONT SHOCK ABSORBER AND FRONT ARM .................................. 52

INSTALLATION................................................................................... 53

ELECTRICAL

ELECTRICAL COMPONENTS ...............................................................54

YFM40FP/YFM400FW WIRING DIAGRAM

..................................................................................................54

GEN

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number stamped into the left side of the frame.

MODEL LABEL

The model label information will be needed to order spare parts.

is affixed to the frame. This

INFO

– 1 –

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YFM40FP/YFM400FW

Model code: 4SHK (for CDN)

4SHL (for Europe) 4SHM (for Oceania)

Dimensions:

Overall length 1,956 mm (77.0 in) Overall width 1,155 mm (45.5 in) Overall height 1,144 mm (45.0 in) Seat height 835 mm (32.9 in) Wheelbase 1,210 mm (47.6 in) Minimum ground clearance 215 mm (8.46 in) Minimum turning radius 3,500 mm (137.8 in)

Basic weight:

With oil and full fuel tank 286 kg (631 lb)

Spark plug:

Type DR8EA Manufacturer NGK Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Transmission:

Primary reduction system Spur gear Primary reduction ratio 76/24(3.167) Secondary reduction system Shaft drive Secondary reduction ratio 24/18 × 33/09 (4.889) Transmission type Constant mesh 5-speed forward, 1-speed

reverse Operation Left foot operation Gear ratio 1st 38/13 (2.923)

2nd 34/18 (1.889) 3rd 30/22 (1.364) 4th 26/25 (1.040) 5th 24/29 (0.828)

Sub transmission low 20/24 × 27/15 (1.500)

high 20/24 × 22/20 (0.916)

Reverse gear 36/13 × 27/16 (4.673)

Chassis:

Frame type Steel tube frame Caster angle 2.5˚ Trail 15 mm (0.59 in) Tread (STD) front 850 mm (33.46 in) Tread (STD) rear 820 mm (32.28 in) Toe-in 5 ~ 15 mm (0.20 ~ 0.59 in)

– 2 –

GENERAL SPECIFICATIONS

Model YFM40FP/YFM400FW

Tire:

Type Tubeless Size front AT25 × 8-12

rear AT25 × 10-12

Manufacturer front DUNLOP (for CDN and Europe)

CHENG SHIN (for Oceania)

rear DUNLOP (for CDN and Europe)

CHENG SHIN (for Oceania) Type front KT402 (for CDN and Europe)

C-828 (for Oceania)

rear KT406 (for CDN and Europe)

C-828 (for Oceania)

Tire pressure (cold tire):

Off-road riding

front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm

Brake:

Front brake type Single disc brake

operation Right hand operation

Rear brake type Drum brake

operation Left hand and right foot operation

Electrical:

Ignition system C.D.I. Generator system A.C. magneto Battery type YTX20L-BS Battery capacity 12 V 18 AH

Bulb wattage × quantity:

Headlight 12 V 30 W/30 W × 2 Taillight 12 V 7.5 W × 1 Meter light 12 V 3 W × 1 Neutral indicator light 12 V 1.7 W × 1 Reverse indicator light 12 V 1.7 W × 1 Oil temperature indicator light 12 V 1.7 W × 1

SPEC

, 3.2 ~ 4.0 psi)

– 3 –

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Model YFM40FP/YFM400FW

Piston:

Piston to cylinder clearance 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) <Limit> <0.15 mm (0.0059 in)> Piston size “D” 82.92 ~ 82.97 mm (3.265 ~ 3.267 in)

Measuring point “H” 5.5 mm (0.217 in) Piston off-set 0.5 mm (0.02 in) Piston off-set direction Intake side Piston pin bore inside diameter 19.004 ~ 19.015 mm (0.7482 ~ 0.7486 in) Piston pin outside diameter 18.990 ~ 18.995 mm (0.7476 ~ 0.7478 in)

Carburetor:

I. D. mark 4SHK 20 (for CDN)

4SHL 30 (for Europe and Oceania) Main jet (M.J.) #105 Main air jet (M.A.J.) 0.7 Jet needle (J.N.) 5H26-2 Needle jet (N.J.) N-8 (#786) Pilot air jet (P.A.J.1) 1.0 Pilot air jet (P.A.J.2) 0.9 Pilot outlet (P.O.) 0.75 Pilot jet (P.J.) #45 Pilot screw (P.S.) 2 turns out Bypass 1 (B.P.1) 0.8 Bypass 2 (B.P.2) 0.8 Bypass 3 (B.P.3) 1.0 Valve seat size (V.S.) 2.5 Starter jet (G.S.1) #60 Throttle valve size (Th.V.) #130 Float height (F.H.) 11.4 ~ 13.4 mm (0.45 ~ 0.53 in) Fuel level (F.L.) 1 ~ 2 mm (0.04 ~ 0.08 in)

Engine idle speed 1,350 ~ 1,450 r/min Intake vacuum 33.3 kPa (250 mmHg, 10 inHg)

– 4 –

MAINTENANCE SPECIFICATIONS

CHASSIS

Model YFM40FP/YFM400FW

Front suspension:

Shock absorber travel 67.5 mm (2.66 in) Fork spring free length 229.5 mm (9.04 in) Spring rate (K1) 19.6 N/mm (1.96 kg/mm, 111 lb/in) Stroke (K1) 0 ~ 67.5 mm (0 ~ 2.66 in) Optional spring No

Rear suspension:

Shock absorber travel 75 mm (2.95 in) Spring free length 264.3 mm (10.4 in) Fitting length 221.3 mm (8.71 in) Spring rate (K1) 32.4 N/mm (3.24 kg/mm, 185 lb/in) Stroke (K1) 0 ~ 75 mm (0 ~ 2.95 in) Optional spring No

Front wheel:

Type Disc wheel Rim size 12 × 6.0AT Rim material Steel Rim runout limit radial 2 mm (0.08 in)

lateral 2 mm (0.08 in)

Rear wheel:

Type Disc wheel Rim size 12 × 7.5AT Rim material Steel Rim runout limit radial 2 mm (0.08 in)

lateral 2 mm (0.08 in)

Front disc brake:

Type Single Disc outside diameter × thickness 180 × 3.5 mm (7.09 × 0.14 in) Pad thickness 4.5 mm (0.18 in) <Limit> <1.0 mm (0.04 in)> Master cylinder inside diameter 15.87 mm (0.62 in) Caliper cylinder inside diameter 32 mm (1.26 in) Brake ﬂuid type DOT 4

Brake lever & brake pedal:

Brake lever free play (left) 4 ~ 7 mm (0.16 ~ 0.28 in) Brake pedal position 5 mm (0.2 in) Brake pedal free play 20 ~ 30 mm (0.8 ~ 1.2 in) Throttle lever free play 3 ~ 5 mm (0.1 ~ 0.2 in)

SPEC

– 5 –

MAINTENANCE SPECIFICATIONS

Tightening torques

Tightening torque

Part to be tightened Thread size

Nm m·kg ft·lb

Steering shaft and frame M10 35 3.5 25 Tie-rod and locknut M10 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 15 110 Front brake caliper and steering knuckle M8 30 3.0 22 Front brake disc and wheel hub M8 30 3.0 22 Brake disc guard and steering knuckle M6 7 0.7 5.1 Front brake pipe nut M10 19 1.9 13 Master cylinder and handlebar M6 7 0.7 5.1 Footrest and frame M10 64 6.4 46 Front carrier and frame M8 31 3.1 22 Front carrier and front bumper M6 10 1.0 7.2 Front bumper and frame M8 31 3.1 22 Rear carrier and frame M8 33 3.3 24

SPEC

Remarks

ELECTRICAL

Model YFM40FP/YFM400FW

C.D.I.:

Magneto model/manufacturer F4T466/MITSUBISHI Pickup coil resistance/color 459 ~ 561 Ω at 20 ˚C (68 ˚F)/White/Green –

White/Red C.D.I. unit model/manufacturer F8T36471/MITSUBISHI

Ignition coil:

Model/manufacturer 2JN/YAMAHA Minimum spark gap 6 mm (0.24 in) Primary winding resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 ˚C (68 ˚F)

Charging system:

Type A.C. magneto Model/manufacturer F4T466/MITSUBISHI Nominal output 14 V 15 A at 5,000 r/min Charging coil resistance/color 0.70 ~ 0.86 Ω at 20 ˚C (68 ˚F)/White – White

Rectifier/regulator:

Model/manufacturer SH640E-11/SHINDENGEN Capacity 14 A Withstand voltage 200 V

– 6 –

MAINTENANCE SPECIFICATIONS

Model YFM40FP/YFM400FW

Electric starter system:

Type Constant mesh type Starter motor

Model/manufacturer DBEDU/DENSO Output 0.7 kW Armature coil resistance 0.011 ~ 0.013 Ω at 20 ˚C (68 ˚F) Brush overall length 12 mm (0.47 in) <Limit> <8.5 mm (0.33 in)> Spring force 6.37 ~ 9.32 N (637 ~ 932 g, 22.5 ~ 32.9 oz) Commutator diameter 28 mm (1.10 in) <Wear limit> <27 mm (1.06 in)> Mica undercut 0.6 mm (0.02 in)

Starter relay

Model/manufacturer MS5E-691/JIDECO Amperage rating 180 A Coil winding resistance 4.18 ~ 4.62 Ω at 20 ˚C (68 ˚F)

Fan motor relay:

Model/manufacturer 29U/MATSUSHITA Coil winding resistance 72 ~ 88

Thermo unit:

Model/manufacturer 4SH/DENSO

Horn: (Europe and Oceania only)

Type Plane Model/manufacturer MF-12/NIKKO

Circuit breaker:

Type Fuse Amperage for individual circuit

Main fuse 30 A × 1 Headlight fuse 15 A × 1 Signaling system fuse 10 A × 1 Ignition fuse 10 A × 1 Auxiliary DC jack fuse 10 A × 1 Reserve fuse 30 A × 1

15 A × 1

10 A × 1

Ω

SPEC

– 7 –

CABLE ROUTING

Rear brake switch

Rear brake cable

Starter cable

Auxiliary DC jack lead

Front brake hose

Throttle cable

Horn (for Europe and Oceania)

Speedometer cable

CABLE ROUTING

Speedometer lead

Main switch lead

Oil temperature indicator light lead

Handlebar switch lead

Reverse control cable 2

D Differential gear case breather hose

SPEC

– 8 –

CABLE ROUTING

Å Fasten the handlebar switch lead and rear brake switch lead to the handlebar with the plastic band. ı Route the fuel tank breather hose through the hole in the handlebar cover. Ç Fasten the handlebar switch lead, rear brake switch lead and horn lead to the handlebar with the plastic

band. (for Europe and Oceania)

Î Fasten the speedometer lead, main switch lead, oil temperature indicator light lead, handlebar switch lead,

rear brake switch lead and horn lead with a plastic locking tie.

SPEC

– 9 –

CABLE ROUTING

SPEC

1 Horn lead (for Europe and Oceania) 2 Taillight lead 3 Fuel tank breather hose 4 Starter cable 5 CDI unit 6 Positive battery lead 7 Negative battery lead 8 Carburetor overflow hose 9 Reverse switch lead 0 Starter motor lead A CDI magneto lead

B Ground lead C Oil hose D Auxiliary DC jack E Rear brake breather hose 6 Final gear case breather hose 7 Carburetor air vent hose 8 Reverse control cable 2 9 Throttle cable

– 10 –

CABLE ROUTING

SPEC

Å Fasten the reverse control cable 2 to the frame

with the plastic clip.

ı Fasten the reverse control cable 2, rear brake

breather hose and final gear case breather hose to the frame with the plastic band.

Ç Fasten the neutral switch lead, CDI magneto

lead, reverse switch lead and negative battery lead to the frame with the plastic band.

Î Fasten the taillight lead to the frame with the

plastic band.

‰ Fasten the wire harness, negative battery lead

and starter motor lead to the frame with a plastic locking tie.

Ï Fasten the starter motor lead to the frame with

the plastic band.

– 11 –

CABLE ROUTING

SPEC

1 Rear brake rod 2 Reverse control cable 2 3 Speedometer cable 4 Reverse control cable 1 5 Starter motor lead 6 Rear brake cable 7 Wire harness 8 Differential gear case breather

hose

9 Fan motor breather hose 0 Oil hose

Å Fasten the wire harness and speedometer cable to the frame

with the metal band.

ı Fasten the wire harness to the frame with the plastic band. Ç Fasten the differential gear case breather hose to the frame

with the plastic clip.

Î Pass the reverse control cable 1 through the cable guide. ‰ Pass the rear brake cable through the cable guide. Ï Align the portion of the wire harness marked with white tape

with the guide.

– 12 –

+ 43 hidden pages