Yamaha YFM400FWA 2000 5GH3-AE1 Manuals

Manuals and User Guides for Yamaha YFM400FWA 2000 5GH3-AE1. We have 3 Yamaha YFM400FWA 2000 5GH3-AE1 manuals available for free PDF download: Service Manual, Assembly Manual

Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual

Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual (381 pages)

Brand: Yamaha | Category: Engine | Size: 15.61 MB

Table of Contents

Table of Contents

6
- Specifications
  3
  - How to Use this Manual
    4
  - Table of Contents
    6
- Chapter 1. General Information
  10
- Machine Identification
  10
  - Vehicle Identification Number
    10
  - Model Label
    10
- Features
  11
  - Liquid Cooling Engine
    11
  - Park Position
    11
- Important Information
  12
  - Preparation for Removal Procedures
    12
  - Replacement Parts
    12
  - Gaskets, Oil Seals and O-Rings
    12
  - Lock Washers/Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    13
  - Circlips
    13
- Checking of Connections
  14
- Special Tools
  15
2 Spec

21
- Specifications
  21
- Chapter 2
  23
- General Specifications
  23
- Engine
  27
  - Maintenance Specifications
    27
- Chassis
  37
- Electrical
  41
  - How to Use the Conversion Table
    43
  - General Torque Specifications
    43
  - Lubrication Points and Lubricant Types
    44
    
    Engine
    44
  - Coolant Flow Diagrams
    45
  - Oil Flow Diagrams
    47
  - Cable Routing
    50
- Insp Adj
  57
Periodic Inspections and Adjustments Chapter 3.

58
- Chapter 3. Periodic Inspections and Adjustments
  60
- Introduction
  60
- Periodic Maintenance/Lubrication Intervals
  60
- Seat, Carriers, Fenders and Fuel Tank
  62
  - Seat and Side Panels
    62
  - Front Carrier, Front Bumper and Front Fender
    63
  - Rear Carrier and Rear Fender
    65
  - Fuel Tank
    67
- Footrest Boards
  68
- Engine
  69
  - Valve Clearance Adjustment
    69
  - Timing Chain Adjustment
    72
  - Idling Speed Adjustment
    73
  - Throttle Lever Free Play Adjustment
    73
  - Speed Limiter Adjustment
    75
  - Starter Lever Free Play Adjustment
    76
  - Spark Plug Inspection
    77
  - Ignition Timing Check
    78
  - Compression Pressure Measurement
    79
  - Engine Oil Level Inspection
    81
  - Engine Oil Replacement
    82
  - Air Filter Cleaning
    85
  - Coolant Level Inspection
    87
  - Coolant Replacement
    88
  - Coolant Temperature Indicator Light Check
    92
  - V-Belt Inspection
    92
- Chassis
  94
  - Front Brake Adjustment
    94
  - Rear Brake Adjustment
    94
  - Brake Fluid Level Inspection
    97
  - Front Brake Pad Inspection
    98
  - Rear Brake Pad Inspection
    98
  - Brake Hose Inspection
    99
  - Air Bleeding (Hydraulic Brake System)
    99
  - Select Lever Control Cable and Shift Rod Adjustment
    101
  - Final Gear Oil Level Inspection
    102
  - Final Gear Replacement
    103
  - Differential Gear Oil Inspection
    104
  - Differential Gear Oil Replacement
    104
  - Constant Velocity Joint Dust Boot Inspection
    105
  - Steering System Inspection
    106
  - Toe-In Adjustment
    106
  - Front Shock Absorber Adjustment
    108
  - Rear Shock Absorber Adjustment
    108
  - Tire Inspection
    108
  - Wheel Inspection
    111
  - Cable Inspection and Lubrication
    111
  - Levers, Pedal, Etc. Lubrication
    112
- Electrical
  113
  - Battery Inspection
    113
  - Fuse Inspection
    119
  - Headlight Beam Adjustment
    120
  - Headlight Bulb Replacement
    120
Chapter 4. Engine

123
- Engine Removal
  127
  - Air Ducts, Muffler and Exhaust Pipe
    127
  - Select Lever Unit and Coolant Reservoir
    128
  - Hoses and Leads
    129
  - Engine Mounting Bolts
    130
  - Engine Installation
    132
- Cylinder Head
  133
  - Cylinder Head Removal
    135
  - Tappet Cover Inspection
    136
  - Timing Chain Tensioner Inspection
    136
  - Camshaft Sprocket Inspection
    136
  - Cylinder Head Inspection
    137
  - Cylinder Head Installation
    138
- Camshaft, Rocker Arms and Valves
  141
  - Camshaft and Rocker Arm Removal
    143
  - Valve and Valve Spring Removal
    143
  - Camshaft Inspection
    144
  - Rocker Arm and Camshaft Inspection
    144
  - Valve and Valve Spring Inspection
    145
  - Valve and Valve Spring Installation
    150
  - Camshaft and Rocker Arm Installation
    151
- Cylinder and Piston
  152
  - Piston Removal
    153
  - Cylinder and Piston Inspection
    153
  - Piston Ring Inspection
    155
  - Piston Pin Inspection
    156
  - Piston Installation
    157
  - Cylinder Installation
    158
- Recoil Starter and CDI Magneto
  159
  - CDI Magneto Removal
    159
  - Recoil Starter Disassembly
    162
  - CDI Magneto Inspection
    162
  - Starter Clutch Inspection
    163
  - Starter Pulley Inspection
    164
  - Recoil Starter Inspection
    164
  - Recoil Starter Assembly
    164
  - CDI Magneto Installation
    165
- Primary and Secondary Sheaves
  168
  - Primary Sheave
    170
  - Secondary Sheave
    171
  - Primary and Secondary Sheaves Removal
    172
  - Secondary Sheave Disassembly
    172
  - Primary Sheave Inspection
    173
  - Secondary Sheave Inspection
    173
  - Primary Sheave Assembly
    174
  - Secondary Sheave Assembly
    174
  - Primary and Secondary Sheaves Installation
    176
- Clutch
  177
  - Clutch Removal
    179
  - Clutch Inspection
    179
  - Clutch Installation
    180
- Crankcase
  182
  - Starter Motor, Timing Chain and Oil Filter
    182
  - Crankcase
    183
  - Crankcase Bearing
    185
  - Oil Pump Drive Gear Removal
    186
  - Crankcase Separation
    186
  - Timing Chain and Guide Inspection
    187
  - Oil Strainer and Oil Delivery Pipe Inspection
    187
  - Crankcase Inspection
    188
  - Bearings and Oil Seals Inspection
    188
  - Crankcase Assembly
    188
  - Shift Lever Installation
    189
  - Oil Pump Drive Gear Installation
    190
- Crankshaft and Oil Pump
  191
  - Oil Pump
    192
  - Crankshaft Removal
    193
  - Oil Pump Inspection
    193
  - Crankshaft Inspection
    194
  - Crankshaft and Balancer Installation
    195
- Transmission
  196
  - Shift Fork Inspection
    198
  - Shift Cam Inspection
    198
  - Transmission Inspection
    199
  - Transmission Installation
    199
- Middle Gear
  201
  - Middle Drive Shaft
    201
  - Middle Driven Shaft
    202
  - Middle Drive Shaft Removal
    204
  - Middle Driven Shaft Removal
    204
  - Inspection
    206
  - Middle Drive and Driven Gear Shim Selection
    207
  - Middle Driven Shaft Installation
    210
  - Middle Drive Shaft Installation
    212
  - Gear Lash Measurement
    212
5 Cool

216
- Chapter 5. Cooling System
  218
- Radiator
  219
  - Radiator Inspection
    220
  - Radiator Installation
    221
- Thermostat
  222
  - Thermostat Inspection
    223
  - Thermostat Installation
    223
- Water Pump
  224
  - Water Pump Disassembly
    225
  - Water Pump Inspection
    226
  - Water Pump Assembly
    227
Carb Chapter 6. Carburetion

231
- Carburetor
  233
  - Carburetor Inspection
    236
  - Carburetor Assembly
    238
  - Fuel Level Adjustment
    239
- Chapter 6. Carburetion
  233
7 Drive

242
- Chapter 7. Drive Train
  244
- Troubleshooting
  244
- Constant Velocity Joints and Differential Gear
  247
  - Ring Gear Removal
    252
  - Constant Velocity Joint Inspection
    252
  - Differential Gear Inspection
    252
  - Constant Velocity Joint Assembly
    253
  - Differential Gear Assembly
    254
  - Differential Gear Lash Measurement and Adjustment
    254
  - Differential Gear Operation Check
    256
- Rear Axle/Final Drive Gear and Drive Shaft
  260
  - Rear Axle Removal
    260
  - Final Drive Roller Bearing Removal and Reassembly
    261
  - Final Drive Pinion Gear and Ring Gear Positioning
    262
  - Rear Axle Inspection
    266
  - Drive Shaft Inspection
    267
  - Final Drive Gear Inspection
    267
  - Final Gear Lash Measurement and Adjustment
    268
  - Final Drive Gear Assembly
    270
  - Final Drive Gear Installation
    270
- Chas
  272
Chapter 8. Chassis

273
- Front and Rear Wheels
  275
  - Front Wheels
    275
  - Rear Wheels
    276
  - Wheel Inspection
    277
  - Wheel Hub Inspection
    277
  - Brake Disc Inspection
    278
  - Wheel Hub/Brake Drum Installation
    278
  - Wheel Installation
    278
- Front and Rear Brakes
  280
  - Front Brake Pads
    280
  - Rear Brake Pads
    281
  - Front Brake Pad Replacement
    282
  - Rear Brake Pad Replacement
    284
  - Front Brake Master Cylinder
    286
  - Rear Brake Master Cylinder
    288
  - Master Cylinder Inspection
    291
  - Front Brake Master Cylinder Assembly
    292
  - Rear Brake Master Cylinder Assembly
    292
  - Front Brake Master Cylinder Installation
    293
  - Rear Brake Master Cylinder Installation
    294
  - Front Brake Caliper
    296
  - Rear Brake Caliper
    298
  - Front and Rear Brake Caliper Disassembly
    300
  - Front and Rear Brake Caliper Inspection
    300
  - Front and Rear Brake Caliper Assembly
    301
  - Front Brake Caliper Installation
    301
  - Rear Brake Caliper Installation
    303
- Steering System
  304
  - Handlebar
    304
  - Rear Brake Switch Removal
    306
  - Handlebar Inspection
    306
  - Handlebar Installation
    306
  - Rear Brake Lever Installation
    306
  - Master Cylinder Assembly Installation
    307
  - Steering Stem
    308
  - Bearing Retainer Removal
    310
  - Steering Stem Inspection
    310
  - Bearing Retainer Installation
    310
  - Cable Guide Installation
    310
  - Tie Rod and Steering Knuckle
    311
  - Steering Knuckle Removal
    312
  - Tie Rod Inspection
    312
  - Steering Knuckle Inspection
    312
  - Ball Joint Inspection
    313
  - Tie Rod Installation
    313
- Front Arms and Front Shock Absorber
  314
  - Front Arms Removal
    316
  - Front Arm Inspection
    316
  - Front Shock Absorber Inspection
    316
  - Front Arms and Front Shock Absorber Installation
    316
- Rear Shock Absorber and Swingarm
  318
  - Swingarm Removal
    319
  - Rear Shock Absorber Inspection
    319
  - Swingarm Inspection
    320
  - Rubber Boot Inspection
    320
  - Rubber Boot Installation
    320
- Elec
  321
Chapter 9. Electrical

322
- Electrical Components
  324
- Switch Inspection
  325
  - Inspecting a Switch Shown in the Manual
    325
  - Switch Continuity Inspection
    326
- Ignition System
  328
  - Circuit Diagram
    328
  - Troubleshooting
    329
- Electric Starting System
  334
  - Circuit Diagram
    334
  - Starting Circuit Operation
    335
  - Troubleshooting
    336
  - Starter Motor
    336
  - Starter Motor Inspection
    341
  - Starter Motor Assembly
    342
- Charging System
  343
  - Circuit Diagram
    343
  - Troubleshooting
    344
- Lighting System
  346
  - Circuit Diagram
    346
  - Troubleshooting
    347
  - Lighting System Check
    349
- Signal System
  352
  - Circuit Diagram
    352
  - Troubleshooting
    353
  - Signal System Check
    355
- Cooling System
  363
  - Circuit Diagram
    363
  - Troubleshooting
    364
- 2Wd/4Wd Selecting System
  368
  - Circuit Diagram
    368
- Trbl Shtg
  372
  - Troubleshooting Trbl
    373
  - Troubleshooting
    375

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Yamaha YFM400FWA 2000 5GH3-AE1 Assembly Manual

Yamaha YFM400FWA 2000 5GH3-AE1 Assembly Manual (42 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 2.07 MB

Table of Contents

Avant-Propos
2
Setup Procedures
8
Montage
8
Fuel Tank Cap
13
Front Wheel/Roue Avant
14
Cable Routing
21
Adjustments and Predelivery Service
22
Battery Inspection
23
Inspection de la Batterie
23
Engine Oil Level Inspection
26
Final Gear Oil Level Inspection
27
Coolant Level Inspection
28
Idling Speed Adjustment
29
Réglage du Ralenti
29
Throttle Lever Free Play Adjustment
30
Rear Brake Adjustment
30
Réglage du Frein Arrière
30
Air Bleeding (Hydraulic Brake System)
33
Rear Shock Absorber Adjustment
35
Réglage de L'amortisseur Arrière
35
Headlight Beam Adjustment
35
Equipement Standard
36
Tightening Torque
37
Couple de Serrage
39

Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual

Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual (31 pages)

Brand: Yamaha | Category: Motorcycle | Size: 1.28 MB

Table of Contents

Specifications
3
How to Use this Manual
4
Periodic Inspection and
5
- Table of Contents
  8
- Chapter 1. General Information
  10
- Machine Identification
  10
- Model Label
  10
- Vehicle Identification Number
  10
- Features
  11
- Liquid Cooling Engine
  11
- Park Position
  11
- Gaskets, Oil Seals and O-Rings
  12
- Important Information
  12
- Preparation for Removal Procedures
  12
- Replacement Parts
  12
- Bearings and Oil Seals
  13
- Circlips
  13
- Lock Washers/Plates and Cotter Pins
  13
- Checking of Connections
  14
- Special Tools
  15
- General Specifications
  23
- Maintenance Specifications
  27

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