Yamaha YFM400FWA 2000 5GH3-AE1 User manual

SERVICEMANUAL
YFM400FWA(M)5GH3-AE1
2000

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.

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.
N
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 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. It is located in the upper left corner of the page.
3rd title 3 : 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 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-to-read way by the use of symbol
marks 6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 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 8 are given in
addition to the exploded diagram and the job instruction chart.

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 Troubleshooting
Illustrated symbols A to H are used to
identify the specifications appearing in the
text.
A Can be serviced with engine mounted
B Filling fluid
C Lubricant
D Special tool
E Torque
F Wear limit, clearance
G Engine speed
H
Ω
, V, A
Illustrated symbols I to N in the exploded
diagrams indicate the types of lubricants
and lubrication points.
I Apply engine oil
J Apply gear oil
K Apply molybdenum disulfide oil
L Apply wheel bearing grease
M Apply lightweight lithium-soap base grease
N 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
12
34
56
78
90
AB
CD
EF
GH
IJK
LMN
OP
GEN
INFO SPEC
INSP
ADJ ENG
COOL CARB
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
GM
E
BLS M
LT New

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

GEN
INFO
1

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 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.