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Table of Contents
Related Manuals for Yamaha YFM 400 FWA P
Summary of Contents for Yamaha YFM 400 FWA P
- Page 1 2002 YFM400FWA 5GH3-AE2 SUPPLEMENTARY SERVICE MANUAL...
- Page 3 Supplementary Service Manual together with the following manual. YFM400FWA(M) 2000 SERVICE MANUAL: 5GH3-AE1 YFM400FWA(P) 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. First Edition, June 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
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Page 4: Important Information
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. -
Page 5: 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 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. - Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical...
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Page 7: Table Of Contents
CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 MAINTENANCE SPECIFICATIONS ............2 ENGINE ....................2 ELECTRICAL ..................4 CABLE ROUTING ..................5 PERIODIC CHECKS AND ADJUSTMENTS ..........15 INTRODUCTION ..................15 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......15 CHASSIS ....................17 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......17 ENGINE ......................18 CYLINDER HEAD ...................18 CYLINDER HEAD INSTALLATION ............18 RECOIL STARTER AND CDI MAGNETO ..........21 TRANSMISSION ..................23... -
Page 9: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5GHL: (CDN) 5GHM: (Europe) 5GHN: (Oceania) Engine: Engine type Liquid-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 401 cm³ 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/cm², 203 psi) at 750 r/min... -
Page 10: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit 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 (0.0004 in) Measuring point 40 mm (1.57 in) ----... - Page 11 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Automatic centrifugal clutch: Clutch shoe thickness 1.5 mm (0.06 in) 1.0 mm (0.04 in) Clutch-in revolution 1,960 ~ 2,240 r/min ---- Clutch-stall revolution 3,300 ~ 3,900 r/min ---- Carburetor: I.D.mark 5GH9 11 ---- Main jet (M.J) #130 ----...
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Page 12: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit C.D.I.: Magneto model/manufacturer F4T46471/MITSUBISHI ---- 459 ~ 561 Ω at 20 °C (68 °F)/ Pickup coil resistance/color ---- /White/Red-White/Green 0.104 ~ 0.127 Ω at 20 °C (68 °F)/ Rotor rotation direction sensing coil resis- ---- tance/color Red-White/Blue... -
Page 13: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch 2 Rear brake cable 3 Front brake hose 4 On command four-wheel drive switch 5 Throttle cable 6 Horn switch – 5 –... - Page 14 SPEC CABLE ROUTING 1 On command four-wheel drive switch lead A Differential gear case breather hose 2 Front brake hose B Fan motor breather hose 3 Throttle cable C Front brake light switch lead 4 Rear brake cable 5 Rear brake switch lead 6 Handlebar switch 7 Starter cable 8 Coolant reservoir breather hose...
- Page 15 SPEC CABLE ROUTING 1 Headlight coupler C Main switch coupler 2 Circuit breaker D Ignition coil lead 3 Terminal 4 Terminal coupler È Connect the headlight lead of the circuit breaker 5 Engine temperature warning light to the headlight on the right side. 6 Four-wheel drive indicator light 7 Neutral indicator light 8 Reverse indicator light...
- Page 16 SPEC CABLE ROUTING 1 Thermo switch È To hole on the front fender. 2 Fuel tank breather hose É Insert the fuel tank into the hole in the handlebar 3 Carburetor drain hose cover. 4 Speedometer cable Ê 10 mm (0.4 in) 5 Coolant reservoir breather hose 6 Coolant reservoir hose 7 Sub-wire harness 1...
- Page 17 SPEC CABLE ROUTING 1 Neutral switch lead C Rectifier/regulator 2 Starter motor lead 3 Negative battery lead 4 Water pump breather hose 5 Speed sensor 6 Carburetor drain hose 7 Wire harness 8 Sub-wire harness 2 9 Ground lead 0 AC magneto lead A Final drive gear case breather hose B Speed sensor È...
- Page 18 SPEC CABLE ROUTING È Fasten the AC magneto lead and starter motor lead with a plastic band. É To hole on the rear fender. Ê 120 mm (4.72 in) È É Ê – 10 –...
- Page 19 SPEC CABLE ROUTING 1 Spark plug lead È Fasten the radiator inlet hose and fan motor 2 Rear brake cable breather hose with a plastic band. 3 Select lever control cable É Pass the rear brake cable through the cable 4 Rear brake reservoir hose guide.
- Page 20 SPEC CABLE ROUTING 1 Fan motor breather hose 2 Cylinder head breather hose 3 Air filter case breather hose 4 Rear brake hose 5 Final drive gear case breather hose – 12 –...
- Page 21 SPEC CABLE ROUTING 1 Fan motor breather hose È 30 mm(1.18 in) 2 Wire harness 3 Positive battery lead 4 Tail/brake light 5 Main fuse 6 Starter relay 7 CDI unit 8 Fuse box 9 Negative battery lead 0 Final drive gear case breather hose È...
- Page 22 SPEC CABLE ROUTING 1 Fan motor breather hose È 70 mm (2.76 in) 2 Front brake hose 3 Wire harness 4 Cylinder head breather hose 5 Throttle cable 6 Final drive gear case breather hose 7 Air vent hose 8 Starter cable 9 Rear brake cable È...
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Page 23: Periodic Checks And Adjustments
• Check toe-in/Adjust if necessary. • Check operation. Axle boots* • Replace if damaged. • Check all chassis fittings and fasteners. Fittings and Fasteners* • Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. – 15 –... - Page 24 PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1. When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2. On the inner parts of the master cylinder and caliper, replace the oil seals every two years. 3.
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Page 25: Chassis
ADJUSTING THE REAR BRAKE LIGHT SWITCH CHASSIS ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. -
Page 26: Engine
CYLINDER HEAD ENGINE CYLINDER HEAD CYLINDER HEAD INSTALLATION 1.Install: Cylinder head 40 Nm (4.0 m • kg, 29 ft • lb) Bolt (M10) 10 Nm (1.0 m • kg, 7.2 ft • lb) Bolt (M6) NOTE: Lubricate the washer with engine oil. Tighten the bolts (M10) in two stages and a crisscross pattern. - Page 27 CYLINDER HEAD NOTE: Be sure the “I” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. Force the camshaft clockwise and counter- clockwise to remove timing chain slack. Insert a screwdriver into the timing chain ten- sioner hole and push the timing chain guide inward.
- Page 28 CYLINDER HEAD 4.Tighten: Camshaft sprocket bolt 1 60 Nm (6.0 m • kg, 43 ft • lb) NOTE: Use the rotor holder 2 to hold the starter pul- ley. Rotor holder: P/N. YU-01235, 90890-01235 5.Check: Camshaft sprocket punch mark Rotor “T” mark Out of alignment →...
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Page 29: Recoil Starter And Cdi Magneto
RECOIL STARTER AND CDI MAGNETO RECOIL STARTER AND CDI MAGNETO Order Job name/Part name Q’ty Remarks CDI magneto removal Remove the parts in the order below. Engine oil Drain. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Seat and side panels Refer to “SEAT AND SIDE PANELS”... - Page 30 RECOIL STARTER AND CDI MAGNETO Order Job name/Part name Q’ty Remarks Pickup coil Stator assembly CDI rotor Refer to “CDI MAGNETO REMOVAL/ Starter wheel gear INSTALLATION”. Woodruff key Bush/washer Starter idle gear shaft Washer/bearing Starter idle gear For installation, reverse the removal procedure.
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Page 31: Transmission
TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Transmission removal Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Chain Clutch dog 2 Shift fork “L” Spring Low wheel gear Secondary shaft Middle driven gear Drive axle assembly Guide bar –... - Page 32 TRANSMISSION Order Job name/Part name Q’ty Remarks Shift fork “R” Spring Shift cam Stopper wheel Clutch dog 1 High wheel gear Stopper lever Spacer/O-ring For installation, reverse the removal procedure. – 24 –...
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Page 33: Electrical
– ELEC ELECTRIC STARTING SYSTEM ELECTRICAL EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM – 25 –... -
Page 34: Troubleshooting
– ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main, ignition) 7.Neutral switch 2.Battery 8.Rear brake switch 3.Starter motor 9.Park switch 4.Starter relay 10.Start switch 5.Main switch 11.Wiring connection (the entire starting sys- 6.Engine stop switch tem) NOTE:... - Page 35 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY WARNING 3.Starter motor A wire that is used as a jumper lead must Connect the battery positive terminal 1 have the equivalent capacity or more as and starter motor cable using a jumper that of the battery lead, otherwise the lead jumper lead may burn.
- Page 36 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY INCORRECT 6.Engine stop switch Refer to “SWITCH INSPECTION”. (Manual No.: 5GH3-AE1) Replace the handlebar switch (right). CORRECT 7.Neutral switch INCORRECT Refer to “SWITCH INSPECTION”. (Manual No.: 5GH3-AE1) Replace the neutral switch. CORRECT 8.Rear brake switch INCORRECT Refer to “SWITCH INSPECTION”.
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Page 37: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 29 –... - Page 38 – ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 5 Main fuse 9 CDI unit C Reverse switch D Neutral switch H Four-wheel drive indicator light I Coolant temperature indicator light J Park switch K Thermo switch L Four-wheel drive fuse O Four-wheel drive switch R Diode S Ignition fuse...
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Page 39: Checking The Signal System
– ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “SWITCH INSPECTION”. - Page 40 – ELEC SIGNAL SYSTEM 2.If the reverse indicator light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2.Reverse switch NO CONTINUITY Refer to “SWITCH INSPECTION”. (Manual No.: 5GH3-AE1) Replace the reverse switch.
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Page 41: Yfm400Fwa(P) 2002 Wiring Diagram
YFM400FWA(P) 2002 WIRING DIAGRAM 1 CDI magneto 2 Rectifier/regulator L/R Sb Sb L/R 3 Main switch Br/W R/B Sb Br/W W L/Y 4 Battery W/R W/G (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) 5 Main fuse (BLACK) (BLACK) (BLACK) MAIN HARNESS SUB LEAD 3 MAIN HARNESS SUB LEAD 2...