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Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual

Other manuals for YFM400FWA 2000 5GH3-AE1: Service Manual

Summary of YFM400FWA 2000 5GH3-AE1

  • Page 1

    Service manual yfm400fwa ( m ) 5gh3-ae1 2000

  • 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: Notice

    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...

  • 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. 2nd title 2 : this title indicates the sectio...

  • Page 5: Gen

    Eb003000 illustrated symbols illustrated symbols 1 to 0 are printed on the top right of each page and indicate the subject of each chapter. 1 general information 2 specifications 3 periodic inspections and adjustments 4 engine 5 cooling system 6 carburetion 7 drive train 8 chassis 9 electrical 0 tro...

  • Page 6: Table of Contents

    Table of contents general information 1 specifications spec 2 periodic inspection and adjustments 3 engine eng 4 cooling system cool 5 carburetion carb 6 drive train driv 7 chassis chas 8 electrical elec 9 troubleshooting 10 gen info insp adj – + trbl shtg.

  • Page 7: Gen

    Gen info 1.

  • Page 8: Gen

    Gen info chapter 1. General information machine identification .........................................................................1-1 vehicle identification number ..................................................1-1 model label ...................................................................

  • Page 9: Gen

    Gen info.

  • Page 10: Gen

    1 - 1 gen info 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..

  • Page 11: Gen

    1 - 2 gen 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 stop...

  • Page 12: Gen

    1 - 3 gen info 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 part...

  • Page 13: Gen

    Gen info 1 - 4 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 t...

  • Page 14: Gen

    1 - 5 gen info checking of connections 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: ●...

  • Page 15: Gen

    Gen info 1 - 6 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 dif...

  • Page 16: Gen

    Gen info 1 - 7 special tools kit 90890-04088 bolt 90890-01275 buffer boss installer set crankshaft installer bolt these tools are used to install the crankshaft. Yu-90050 crankshaft installer set these tools are used to install the crankshaft. Adapter ym-33279 spacer 90890-04060 ym-90070-a adapter (...

  • Page 17: Gen

    Gen info 1 - 8 special tools 90890-04134 ym-04134 sheave spring compressor this tool is needed when removing or installing the secondary sheave spring. 90890-04135 ym-04135 sheave fixed block this tool is needed when removing or installing the secondary sheave spring. 90890-01404 ym-01404 flywheel p...

  • Page 18: Gen

    Gen info 1 - 9 special tools 90890-03112 yu-03112 pocket tester this instrument is needed for checking the electrical system. 90890-03113 engine tachometer this tool is needed for observing engine rpm. Yu-8036-a inductive tachometer this tool is needed for observing engine rpm. 90890-03141 ym-33277-...

  • Page 19: Gen

    Gen info 1 - 10 special tools 90890-04128 ym-04128 bearing retainer wrench this tool is needed when removing or installing the middle driven pinion gear bearing retainer. 90890-04129 ym-04129 pinion gear fix clamp this tool is used to hold the shift cam. 90890-06754 ignition checker this instrument ...

  • Page 20: Spec

    Spec 2.

  • Page 21: Spec

    Spec chapter 2. Specifications general specifications .........................................................................2-1 maintenance specifications ...............................................................2-5 engine .......................................................................

  • Page 22: Spec

    Spec.

  • Page 23: Spec

    2 - 1 spec 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 1,225 mm...

  • Page 24: Spec

    2 - 2 spec 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: type regular unleaded gasoline (for cdn, gb, f, ch) unl...

  • Page 25: Spec

    2 - 3 spec 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) item standard general specifications.

  • Page 26: Spec

    2 - 4 spec tire pressure (cold tire): maximum load* 210 kg (463 lb) off-road riding front 22 ~ 28 kpa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4.0 psi) rear 22 ~ 28 kpa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4.0 psi) *load in total weight of rider accessories brake: front brake type dual disc brake operation right hand o...

  • Page 27: Spec

    2 - 5 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) 84.600 mm (3.3307 in) taper limit ---- 0.05 mm (0.0016 in) out of round limit ---- 0.01 mm (0.0004 in) camshaft: drive metho...

  • Page 28: Spec

    2 - 6 spec 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 (0.4717 ~ 0.4721 in) 11.951 mm (0.4705 in) arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.003...

  • Page 29: Spec

    2 - 7 spec stem runout limit ---- 0.01 mm (0.0004 in) valve seat width in 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- ex 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- valve spring: inner spring free length in 39.9 mm (1.57 in) 37.9 mm (1.49 in) ex 39.9 mm (1.57 in) 37.9 mm (1.49 in) set length (valve closed) in...

  • Page 30: Spec

    2 - 8 spec compressed pressure (installed) in 235.4 ~ 251.1 n (24.00 ~ 25.60 kg, 52.92 ~ 56.45 lb) ---- ex 235.4 ~ 251.1 n (24.00 ~ 25.60 kg, 52.92 ~ 56.45 lb) ---- tilt limit in 2.5˚/1.6 mm (2.5˚/0.06 in) ex 2.5˚/1.6 mm (2.5˚/0.06 in) direction of winding (top view) in clockwise ---- ex clockwise -...

  • Page 31: Spec

    2 - 9 spec 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 (0.0157 ~ 0.0236 in) 0.95 mm (0.0374 in) side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.13 mm (0.0051 in) oil ring dimensions (b × t) 2.8 × 2.8 mm (0.1102 × 0.1102 in)...