Yamaha 2000 YFM400FWA Service Manual
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Yamaha 2000 YFM400FWA Service Manual

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YFM400FWA
M
2000
(
)
5GH3-AE1
SERVICE MANUAL

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Summary of Contents for Yamaha 2000 YFM400FWA

  • Page 1 YFM400FWA 2000 5GH3-AE1 SERVICE MANUAL...
  • Page 2 YFM400FWA(M) 2000 SERVICE MANUAL ©1999 by Yamaha Motor Co., Ltd. First Edition, July 1999 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

  • Page 3: Specifications

    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 mainte- nance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.

  • Page 4: How To Use This Manual

    EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated sym- bols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

  • Page 5: Periodic Inspection And

    EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on SPEC the top right of each page and indicate the INFO subject of each chapter. 1 General information INSP 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion COOL CARB...
  • Page 6 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND INSP ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETION CARB DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO...

  • Page 8: Table Of Contents

    INFO CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION .................1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 LIQUID COOLING ENGINE ..............1-2 PARK POSITION ...................1-2 IMPORTANT INFORMATION ...............1-3 PREPARATION FOR REMOVAL PROCEDURES .........1-3 REPLACEMENT PARTS ................1-3 GASKETS, OIL SEALS AND O-RINGS ..........1-3 LOCK WASHERS/PLATES AND COTTER PINS ........1-4 BEARINGS AND OIL SEALS ..............1-4 CIRCLIPS ....................1-4...
  • Page 9 INFO...

  • Page 10: Chapter 1. General Information

    MACHINE IDENTIFICATION INFO 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.

  • Page 11: Features

    FEATURES INFO FEATURES LIQUID COOLING ENGINE Compact liquid cooled 45˚ inclined engine. A liquid cooling system has been incorpo- rated for stable power and engine endur- ance. 1 Radiator 2 Thermo switch 3 Fan motor PARK POSITION When the drive select lever is shifted into the park position, a stopper lever is engaged into the stopper gear preventing the drive select lever and transmission from...

  • Page 12: Important Information

    5.Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in func- tion and appearance, but inferior in qual- ity.

  • Page 13: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cot- ter 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 vis-...

  • Page 14: Checking Of Connections

    CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, 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 →...

  • Page 15: Special Tools

    SPECIAL TOOLS INFO 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.
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Buffer boss installer set Crankshaft installer bolt 90890-04088 Bolt These tools are used to install the 90890-01275 crankshaft. Crankshaft installer set YU-90050 These tools are used to install the crankshaft. Adapter (#11) Adapter Spacer (crankshaft installer)
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Sheave spring compressor 90890-04134 This tool is needed when removing or YM-04134 installing the secondary sheave spring. Sheave fixed block 90890-04135 This tool is needed when removing or YM-04135 installing the secondary sheave spring.
  • Page 18 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Pocket tester 90890-03112 YU-03112 This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing engine rpm. Inductive tachometer YU-8036-A This tool is needed for observing engine rpm.
  • Page 19 This instrument is necessary for check- ing the ignition system components. Dynamic spark tester YM-34487 This instrument is necessary for check- ing the ignition system components. Yamaha bond No. 1215 ® Bond Sealant (Quick Gasket 90890-85505 Sealant This sealant (bond) is used on crank- ACC-11001-05-01 case mating surfaces, etc.
  • Page 20 SPEC...
  • Page 21 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS.................2-1 MAINTENANCE SPECIFICATIONS...............2-5 ENGINE ....................2-5 CHASSIS ....................2-15 ELECTRICAL ..................2-19 HOW TO USE THE CONVERSION TABLE ..........2-21 GENERAL TORQUE SPECIFICATIONS ............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 COOLANT FLOW DIAGRAMS ..............2-23 OIL FLOW DIAGRAMS ................2-25 CABLE ROUTING ..................2-28...
  • Page 22 SPEC...

  • Page 23: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5GH3 : (For CDN) 5GH4 : (For GB, F, CH) 5GH5 : (For Oceania) Dimensions: Overall length 1,965 mm (77.36 in) Overall width 1,070 mm (42.13 in) Overall height 1,120 mm (44.09 in) Seat height 820 mm (32.28 in) Wheelbase...
  • Page 24 SPEC GENERAL SPECIFICATIONS Item Standard Differential gear case oil Periodic oil change 0.35 L (0.31 lmp qt, 0.37 US qt) Total amount 0.40 L (0.35 lmp qt, 0.42 US qt) Radiator capacity (including all routes) 1.1 L (0.97 lmp qt, 1.16 US qt) Air filter: Wet type element Fuel:...
  • Page 25 SPEC GENERAL SPECIFICATIONS Item Standard Manufacturer front DUNLOP (For CDN, GB, F, CH) CHENG SHIN (For Oceania) rear DUNLOP (For CDN, GB, F, CH) CHENG SHIN (For Oceania) Type front KT123 (For CDN, GB, F, CH) C828 (For Oceania) rear KT127 (For CDN, GB, F, CH) C828 (For Oceania) 2 - 3...
  • Page 26 SPEC 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 , 3.2 ~ 4.0 psi) rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) *Load in total weight of rider accessories Brake:...

  • Page 27: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 84.500 ~ 84.510 mm 84.600 mm (3.3268 ~ 3.3272 in) (3.3307 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links 92RH2015/116 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Shaft outside diameter 11.981 ~ 11.991 mm 11.951 mm (0.4717 ~ 0.4721 in) (0.4705 in) Arm-to-shaft clearance 0.009 ~ 0.037 mm 0.08 mm...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) Valve spring: Inner spring Free length 39.9 mm (1.57 in) 37.9 mm (1.49 in)
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Compressed pressure (installed) 235.4 ~ 251.1 N (24.00 ~ ---- 25.60 kg, 52.92 ~ 56.45 lb) 235.4 ~ 251.1 N (24.00 ~ ---- 25.60 kg, 52.92 ~ 56.45 lb) Tilt limit 2.5˚/1.6 mm (2.5˚/0.06 in) 2.5˚/1.6 mm (2.5˚/0.06 in) Direction of winding...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring Type Taper ---- Dimensions (B × T) 1.2 × 3.6 mm ---- (0.0472 × 0.1417 in) End gap (installed) 0.4 ~ 0.6 mm 0.95 mm (0.0157 ~ 0.0236 in) (0.0374 in) Side clearance 0.03 ~ 0.07 mm 0.13 mm (0.0012 ~ 0.0028 in)

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2000 yfm400fwam

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