Yamaha 2002 YFM400FWA Service Manual Download | Manualshive

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YFM400FWA

(

P

)

5GH3-AE2

SUPPLEMENTARY

SERVICE MANUAL

2002

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Summary of Contents for 2002 YFM400FWA

Page 1: ...YFM400FWA P 5GH3 AE2 SUPPLEMENTARY SERVICEMANUAL 2002 ...

Page 2: ......

Page 3: ...res it is necessary to use this 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 is expressly prohibited ...

Page 4: ...fications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE 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 ...

Page 5: ...ntify 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 t...

Page 6: ...clearance E Engine speed F Ω V A Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease Illustrated symbols N to O in the exploded diagrams indic...

Page 7: ...IC 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 ELECTRICAL 25 ELECTRIC STARTING SYSTEM 25 CIRCUIT DIAGRAM 25 TROUBLESHOOTING 26 SIGNAL SYSTEM 29 CIRCUIT DIAGRAM 29 CHECKING THE SIGNAL SYSTEM 31 YFM400FWA P 2002 WIRING DIAGRAM ...

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Page 9: ...rting system Electric and recoil starter Lubrication system Wet sump Tire pressure cold tire Maximum load 210 kg 463 Ib Off road riding front 22 28 kPa 0 22 0 28 kg cm 3 2 4 1 psi rear 22 28 kPa 0 22 0 28 kg cm 3 2 4 1 psi Load in total weight of rider accessories Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX20L BS Battery capacity 12 V 18 AH Bulb wattage quanti...

Page 10: ...er 12 000 12 018 mm 0 4724 0 4731 in 12 078 mm 0 4755 in 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 0031 in Piston Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in 0 15 mm 0 0059 in Piston size D 84 445 84 460 mm 3 3246 3 3252 in Measuring point H 5 mm 0 20 in Piston off set 0 5 mm 0 0200...

Page 11: ...70 Starter jet G S 2 0 9 Throttle valve size Th V 90 Float height F H 13 mm 0 51 in Fuel level F L 3 4 mm 0 12 0 16 in Engine idle speed 1 450 1 550 r min Intake vacuum 32 kPa 240 mmHg 9 45 inHg Oil filter type Foam Oil pump Oil pump type Trochoid Tip clearance A or B 0 15 mm 0 006 in 0 2 mm 0 008 in Side clearance 0 04 0 09 mm 0 0016 0 0035 in Bypass valve setting pressure 78 118 kPa 0 78 1 18 kg...

Page 12: ...oil Model manufacturer 2JN MORIYAMA 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 generator Model manufacturer F4T464 MITSUBISHI Nominal output 14 V 210 W 5 000 r min Charging coil resistance color 0 70 0 86 Ω at 20 C 68 F White White Rectifier regulator Type Semi conductor ...

Page 13: ... 5 SPEC 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 1 2 3 4 5 6 CABLE ROUTING ...

Page 14: ...witch lead 6 Handlebar switch 7 Starter cable 8 Coolant reservoir breather hose 9 Sub wire harness 1 to fan motor coupler 0 Sub wire harness 1 to gear motor and four wheel drive switch A Differential gear case breather hose B Fan motor breather hose C Front brake light switch lead C 1 2 3 4 5 6 7 8 9 0 A B CABLE ROUTING ...

Page 15: ...ral indicator light 8 Reverse indicator light 9 Parking indicator light 0 Coolant reservoir breather hose A Differential gear case breather hose B Indicator light coupler C Main switch coupler D Ignition coil lead È Connect the headlight lead of the circuit breaker to the headlight on the right side 3 4 5 6 7 8 9 0 A 1 1 2 È B 4 B C D A A CABLE ROUTING ...

Page 16: ...eedometer cable 5 Coolant reservoir breather hose 6 Coolant reservoir hose 7 Sub wire harness 1 È To hole on the front fender É Insert the fuel tank into the hole in the handlebar cover Ê 10 mm 0 4 in E E E E D D D D C C B 7 7 6 5 1 2 5 6 3 4 È É A A B C C D D E E Ê CABLE ROUTING ...

Page 17: ...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 C Rectifier regulator A A B 7 B A 0 9 8 A C 6 5 4 3 2 1 È É Ê A B CABLE ROUTING ...

Page 18: ... 10 SPEC 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 A A B 7 B A 0 9 8 A C 6 5 4 3 2 1 È É Ê A B CABLE ROUTING ...

Page 19: ...ke light switch lead È Fasten the radiator inlet hose and fan motor breather hose with a plastic band É Pass the rear brake cable through the cable guide Ê Pass the rear brake reservoir hose select lever control cable and rear brake light switch lead through the cable guide A A A A 1 2 3 4 5 4 É Ê È CABLE ROUTING ...

Page 20: ... 12 SPEC 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 A A 3 5 4 4 3 1 2 B B A A A A 4 CABLE ROUTING ...

Page 21: ...se 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 30 mm 1 18 in A A 1 2 3 4 4 5 6 7 8 9 0 A A È CABLE ROUTING ...

Page 22: ... 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 70 mm 2 76 in A A A A A A 3 1 1 2 3 5 4 1 6 7 4 8 9 È CABLE ROUTING ...

Page 23: ...gap and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter cartridge Replace Engine oil strainer Clean Final gear oil Check o...

Page 24: ...acement 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 Replace the brake hoses every four years or if cracked or damaged ...

Page 25: ... the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b...

Page 26: ...the camshaft to align the camshaft pin 1 with the cylinder head match mark 2 Turn the crankshaft counterclockwise with a wrench Align the T mark 3 on the rotor with the stationary pointer 4 on the crankcase cover When the T mark is aligned with the sta tionary pointer the piston is at the Top Dead Center T D C CAUTION Do not turn the crankshaft during the cam shaft sprocket installation Place the ...

Page 27: ...ad match mark 2 If the marks are aligned tighten the camshaft sprocket bolt If the marks are not aligned change the meshing position of the camshaft sprocket and timing chain 3 Install Timing chain tensioner Installation steps Remove the tensioner cap bolt 1 washer 2 and spring 3 Release the timing chain tensioner one way cam 4 and push the tensioner rod 5 all the way in Install the tensioner 6 wi...

Page 28: ...ighten Camshaft sprocket bolt 1 NOTE Use the rotor holder 2 to hold the starter pul ley 5 Check Camshaft sprocket punch mark Rotor T mark Out of alignment Adjust Rotor holder P N YU 01235 90890 01235 T R 60 Nm 6 0 m kg 43 ft lb ...

Page 29: ...ine oil Drain Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 Seat and side panels Refer to SEAT AND SIDE PANELS in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 1 Recoil starter assembly 1 2 CDI magneto coupler 2 Disconnect 3 Starter pulley 1 Refer to CDI MAGNETO REMOVAL INSTALLATION 4 Crankcase cover left gasket 1 1 5 Dowel pin 2 6 Lead holder 1 ...

Page 30: ...ks 7 Pickup coil 1 8 Stator assembly 1 9 CDI rotor 1 Refer to CDI MAGNETO REMOVAL INSTALLATION 10 Starter wheel gear 1 11 Woodruff key 1 12 Bush washer 1 1 13 Starter idle gear shaft 1 14 Washer bearing 1 1 15 Starter idle gear 1 For installation reverse the removal procedure ...

Page 31: ... Transmission removal Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Driven sprocket 1 2 Chain 1 3 Clutch dog 2 1 4 Shift fork L 1 5 Spring 1 6 Low wheel gear 1 7 Secondary shaft 1 8 Middle driven gear 1 9 Drive axle assembly 1 10 Guide bar 1 ...

Page 32: ...der Job name Part name Q ty Remarks 11 Shift fork R 1 12 Spring 1 13 Shift cam 1 14 Stopper wheel 1 15 Clutch dog 1 1 16 High wheel gear 1 17 Stopper lever 1 18 Spacer O ring 1 1 For installation reverse the removal procedure ...

Page 33: ...r W BROWN BROWN 2WD 4WD Br R R W R B Br G L B Y L B L B G R Y L B Y V W X BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G Y Y B G Y B Y G B G Y B Y G R B R W B B B Y B 0 C B Y B L B B W L B L Y W B W O B W O G W L R Sb G W Sb L R BLACK A BLACK MAIN HARNESS SUB LEAD 1 BLACK B BLACK MAIN HARNESS SUB LEAD 2 BLACK C C C B BLACK MAIN HARNESS SUB LEAD 3 W Sb B R B L B Br W B R ...

Page 34: ...ore trouble shooting 1 Seat 2 Fuel tank side panels 3 Fuel tank 4 Air cleaner case 5 Front carrier 6 Front fender panel Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition Refer to SWITCH INSPECTION Manual No 5GH3 AE1 NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTE...

Page 35: ...s so be sure that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor 4 Starter relay Remove the starter relay from the wire har ness Connect the pocket tester Ω 1 and the battery 12 V to the starter relay terminals CONTINUITY Battery terminal Blue White terminal 1 Battery terminal Blue Black terminal 2 Tester lead Red terminal 3 Tester lead Black termina...

Page 36: ... 8 Rear brake switch Refer to SWITCH INSPECTION Manual No 5GH3 AE1 INCORRECT Replace the rear brake switch CORRECT 9 Park switch Refer to SWITCH INSPECTION Manual No 5GH3 AE1 INCORRECT Replace the park switch CORRECT 10 Start switch Refer to SWITCH INSPECTION Manual No 5GH3 AE1 INCORRECT Replace the handlebar switch left EB803028 11 Wiring connection Check the connections of the entire starting sy...

Page 37: ... L B Br W Sb N O 8 B B Y L Br W B Br R Sb L B Br L G L B L R B M B L B Sb Br W BROWN BROWN 2WD 4WD Br R R W R B Br G L B Y L B L B G R Y L B Y V W X BLACK BLACK Y R Y G L LO HI OFF R W L B ON OFF R B PUSH OFF B B Y G B Y G Y Y B G Y B Y G B G Y B Y G R B R W B B B Y B 0 C B Y B L B B W L B L Y W B W O B W O G W L R Sb G W Sb L R BLACK A BLACK MAIN HARNESS SUB LEAD 1 BLACK B BLACK MAIN HARNESS SUB ...

Page 38: ...rature indicator light JPark switch KThermo switch LFour wheel drive fuse OFour wheel drive switch RDiode SIgnition fuse WEngine stop switch XStart switch ZSignal fuse Front brake light switch Tail brake light Rear brake light switch aNeutral indicator light bReverse indicator light cPark indicator light eHorn switch fHorn ÈFor Europe and Oceania ...

Page 39: ... to SWITCH INSPECTION Manual No 5GH3 AE1 NO CONTINUITY Replace the brake switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from...

Page 40: ...h Refer to SWITCH INSPECTION Manual No 5GH3 AE1 NO CONTINUITY Replace the reverse switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Green Blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb sock...

Page 41: ...Br E R B R B F Br Y G B L L B B P Q P B G W B Br L R W S Br L P P Br L Br R L DARK GRAY L R B 9 f e ON OFF Br B Br B P B B Br 1 CDI magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Speed sensor 9 CDI unit 0 Rear brake switch A Ignition coil B Spark plug C Reverse switch D Neutral switch E Circuit breaker fan motor F Thermo switch G Fan motor H Fou...

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