Yamaha YFM400FWA 2000 5GH3-AE1 Manuale utente

SERVICEMANUAL

YFM400FWA(M)5GH3-AE1

2000

YFM400FWA(M) 2000

SERVICE MANUAL



1999 by Yamaha Motor Co., Ltd.

First Edition, July 1999

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

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. Repairs attempted by anyone without this knowledge

are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications

and significant changes in specifications or procedures will be forwarded to all authorized

Yamaha dealers and will appear in future editions of this manual where applicable.

OTE:

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 ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

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.

WARNING

CAUTION:

NOTE:

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

: This is the title of the chapter with its symbol in the upper right corner of each

page.

2nd title

: This title indicates the section of the chapter and only appears on the first page of

each section. It is located in the upper left corner of the page.

3rd title

: This title indicates a sub-section that is followed by step-by-step procedures

accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify 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

is provided for removal and disassembly jobs.

2. Numbers

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-to-read way by the use of symbol

marks

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements

are given in

addition to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols

are printed on

the top right of each page and indicate the

subject of each chapter.

General information

Specifications

Periodic inspections and adjustments

Engine

Cooling system

Carburetion

Drive train

Chassis

Electrical

Troubleshooting

Illustrated symbols

are used to

identify the specifications appearing in the

text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Ω

, V, A

Illustrated symbols

in the exploded

diagrams indicate the types of lubricants

and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap base grease

Apply molybdenum disulfide grease

Illustrated symbols

Oto Pin the exploded

diagrams indicate where to apply a locking

agent Oand when to install a new part P.

OApply the locking agent (LOCTITE)

PReplace

IJK

LMN

GEN

INFO SPEC

INSP

ADJ ENG

COOL CARB

DRIV

CHAS

–+

ELEC TRBL

SHTG

BLS M

LT New

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

SPEC

PERIODIC INSPECTION AND

ADJUSTMENTS

ENGINE

ENG

COOLING SYSTEM

COOL

CARBURETION

CARB

DRIVE TRAIN

DRIV

CHASSIS

CHAS

ELECTRICAL

ELEC

TROUBLESHOOTING

GEN

INFO

INSP

ADJ

–+

TRBL

SHTG

GEN

INFO

GEN

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

CHECKING OF CONNECTIONS

...................................................................1-5

SPECIAL TOOLS

...........................................................................................1-6

GEN

INFO

1 - 1

GEN

INFO

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

is affixed to the frame.

This information will be needed to order

spare parts.

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