1999 2005 Yamaha Yfm400 Big Bear Atv's Service Manual

YFM400FWNP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-22

5FU-F8197-E1

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM400FWNP. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

YFM400FWNM/YFM400FWNMC SERVICE MANUAL: LIT-11616-13-22 (5FU-F8197-E0)

YFM400FWNP SUPPLEMENTARY SERVICE MANUAL ď›™ 2001 by Yamaha Motor Corporation, U.S.A. First Edition, June 2001 All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A. LIT-11616-15-22

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YFM400FWNP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-22

5FU-F8197-E1

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM400FWNP. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

YFM400FWNM/YFM400FWNMC SERVICE MANUAL: LIT-11616-13-22 (5FU-F8197-E0)

YFM400FWNP SUPPLEMENTARY SERVICE MANUAL ď›™ 2001 by Yamaha Motor Corporation, U.S.A. First Edition, June 2001 All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A. LIT-11616-15-22

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 maintenance 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.

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 ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION: NOTE:

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.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:

This is a chapter with its symbol on the upper right of each page.

2nd title 2:

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3:

This is a final title.

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure 4 is placed between a line of asterisks “*” with each procedure preceded by “●”.

IMPORTANT FEATURES ● Data and a special tool are framed in a box preceded by a relevant symbol 5. ● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8. ● A condition of a faulty component will precede an arrow symbol 9 and the course of action will follow it.

EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

1

EB003000

2

GEN INFO

ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.

SPEC

3

4

CHK ADJ

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting

ENG

5

6

CARB

DRIV

7

8

CHAS

–

ELEC

+

0

Illustrated symbols 0 to F are used to identify the specifications appearing in the text.

A

B

0 Filling fluid A Lubricant B Special tool C Torque D Wear limit, clearance E Engine speed F Ω, V, A

C

D

9

TRBL SHTG

T.

R.

E

F

G

H

G

E J

K B

M

L

M M

LS

N

Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points.

I

S

O

LT

New

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 indicate where to apply a locking agent N and when to install a new part O. N Apply the locking agent (LOCTITE) O Replace

CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATIONS ........................................................ 2 ENGINE................................................................................................ 2 CHASSIS.............................................................................................. 3 ELECTRICAL ....................................................................................... 4 CABLE ROUTING .................................................................................... 5 PERIODIC CHECKS AND ADJUSTMENTS ................................................. 16 INTRODUCTION .................................................................................... 16 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ..................... 16 CHASSIS ................................................................................................ 18 ADJUSTING THE FRONT BRAKE .................................................... 18 ADJUSTING THE REAR BRAKE LIGHT SWITCH............................ 18 DRIVE TRAIN ................................................................................................. 19 CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ............. 19 ASSEMBLING THE DIFFERENTIAL GEAR ...................................... 21 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH .................................................... 22 ELECTRICAL ................................................................................................. 24 CHECKING THE SWITCH ..................................................................... 24 CHECKING THE SWITCH ................................................................. 24 CHECKING A SWITCH SHOWN IN THE MANUAL .......................... 24 IGNITION SYSTEM ................................................................................ 25 CIRCUIT DIAGRAM ........................................................................... 25 TROUBLESHOOTING ....................................................................... 26 ELECTRIC STARTING SYSTEM ........................................................... 31 CIRCUIT DIAGRAM ........................................................................... 31 TROUBLESHOOTING ....................................................................... 32 LIGHTING SYSTEM ............................................................................... 35 CIRCUIT DIAGRAM ........................................................................... 35 CHECKING THE LIGHTING SYSTEM .............................................. 36 SIGNAL SYSTEM ................................................................................... 37 CIRCUIT DIAGRAM ........................................................................... 37 TROUBLESHOOTING ....................................................................... 38 CHECKING THE SIGNAL SYSTEM .................................................. 40 2WD/4WD SELECTING SYSTEM ......................................................... 42 CIRCUIT DIAGRAM ........................................................................... 42 TROUBLESHOOTING ....................................................................... 43 YFM400FWNP WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Model

YFM400FWNP

Model code: Oil type or grade: Engine oil

5FUA (USA)

API service SE, SF, SG type or higher

Final gear oil Differential gear oil Differential gear case oil Periodic oil change Total amount Chassis: Frame type Caster angle Camber angle Kingpin angle Trail Tread (STD) Tread (STD) Toe-in Brake: Front brake Rear brake Bulb wattage × quantity: Headlight Tail/brake light Meter light Neutral indicator light Reverse indicator light Oil temperature warning light Four-wheel drive indicator light

SAE 80 API “GL-4” Hypoid gear oil SAE 80 API “GL-4” Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt) 0.4 L (0.35 Imp qt, 0.42 US qt)

front rear

type operation type operation

Steel tube frame 4° 1° 13° 21 mm (0.83 in) 860 mm (33.86 in) 820 mm (32.28 in) 5 ~ 15 mm (0.20 ~ 0.59 in) Dual disc brake Right hand operation Drum brake Left hand and right foot operation 12 V 30 W/30 W × 2 12 V 5 W/21 W × 1 12 V 3.4 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1

–1–

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Model

YFM400FWNP

Cylinder:

Bore size Out of round limit * Measuring point <Wear limit> Rocker arm/rocker arm shaft: Bearing inside diameter <Limit> Shaft outside diameter <Limit> Arm-to-shaft clearance <Limit> Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum

82.97 ~ 83.02 mm (3.267 ~ 3.269 in) 0.05 mm (0.0020 in) 40 mm (1.57 in) <83.15 mm (3.274 in)> 11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) <12.058 mm (0.4747 in)> 11.961 ~ 11.971 mm (0.4709 ~ 0.4713 in) <11.931 mm (0.4697 in)> 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) <0.08 mm (0.0031 in)>

(M.J.) (M.A.J.) (J.N.) (N.J.) (P.A.J.1) (P.A.J.2) (P.O.) (P.J.) (B.P.1) (B.P.2) (B.P.3) (V.S.) (G.S.1) (G.S.2) (Th.V.) (F.H.) (F.L.)

5FUA 12 #112.5 #70 5EP4-55-3 P-0M (#826) #80 1.3 0.8 #17.5 0.8 0.8 0.8 2.0 #70 0.9 #100 12 ~ 14 mm (0.47 ~ 0.55 in) 3 ~ 4 mm (0.12 ~ 0.16 in) 1,450 ~ 1,550 r/min 33.3 kPa (250 mmHg, 10 inHg)

–2–

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS Model Front suspension: Shock absorber travel Fork spring free length Spring rate (K1) Stroke (K1) Optional spring Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate (K1) Stroke (K1) Optional spring Brake lever & brake pedal: Brake lever free play (at lever end) Brake lever free play (left) Brake pedal position Brake pedal free play Throttle lever free play

YFM400FWNP 102 mm (4.02 in) 318.4 mm (12.5 in) 12.3 N/mm (1.25 kg/mm, 70.2 lb/in) 0 ~ 102 mm (0.00 ~ 4.02 in) No 100 mm (3.94 in) 296 mm (11.7 in) 253 mm (9.96 in) 30.4 N/mm (3.10 kg/mm, 174 lb/in) 0 ~ 100 mm (0.00 ~ 3.94 in) No 0 mm (0 in) 5 ~ 8 mm (0.20 ~ 0.31 in) 5 mm (0.2 in) 20 ~ 30 mm (0.8 ~ 1.2 in) 3 ~ 5 mm (0.1 ~ 0.2 in)

Tightening torques Part to be tightened

Thread size

Engine stay (front-upper) and frame Engine stay (front-lower) and frame Engine stay (front-upper) and engine Engine stay (front-lower) and engine Engine and frame (rear-upper) Engine and frame (rear-under) Differential gear case and frame Steering knuckle and front arm

M8 M8 M8 M10 M10 M10 M10 M12

–3–

Tightening torque Nm

m·kg

ft·lb

34 34 34 69 69 69 64 30

3.4 3.4 3.4 6.9 6.9 6.9 6.4 3.0

24 24 24 50 50 50 46 22

Remarks

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL Model

10° at 1,000 r/min 33° at 5,000 r/min Digital type

Ignition timing (B.T.D.C.)

Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type

YFM400FWNP

Engine speed (× 10³ r/min)

C.D.I.: Magneto model/manufacturer Pickup coil resistance/color C.D.I. unit model/manufacturer Rectifier: Regulator type Model/manufacturer No load regulated voltage Capacity Withstand voltage Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Reserve fuse

F4T423/MITSUBISHI 459 ~ 561 Ω at 20 °C (68 °F)/White/Red – White/Green F8T38673/MITSUBISHI Semi conductor-short circuit SH640E-11/SHINDENGEN 14.1 ~ 14.9 V 14 A 200 V Fuse 30 A × 1 15 A × 1 10 A × 1 10 A × 1 10 A × 1 30 A × 1 15 A × 1 10 A × 1

–4–

CABLE ROUTING

SPEC

CABLE ROUTING È Fasten the front brake light switch lead and the on-command four-wheel drive switch lead with a plastic band. É Fasten the starter cable, rear brake lever switch lead, and handlebar switch (left) lead with a plastic band.

1 Rear brake cable 2 Starter cable 3 Front brake hose 4 Front brake light switch lead 5 On-command four-wheel drive switch lead 6 Throttle cable 7 Fuel tank breather hose 8 Rear brake lever switch lead 9 Handlebar switch (left) lead

–5–

CABLE ROUTING

SPEC

A Headlight lead B Gear motor and four-wheel drive switch lead C Differential gear case breather hose D Auxiliary DC jack connector E Speedometer cable F Front brake hose

1 Throttle cable 2 Reverse control cable 3 Rear brake cable 4 Handlebar switch (left) lead 5 Starter cable 6 Neutral indicator light, reverse indicator light, and meter light lead 7 Rear brake lever switch lead 8 Oil temperature warning light and four-wheel drive indicator light lead 9 Main switch lead 0 Fan motor lead

â&#x20AC;&#x201C;6â&#x20AC;&#x201C;

CABLE ROUTING

SPEC

È Fasten the headlight lead and fan motor lead with a plastic band. É Fasten the gear motor and four-wheel drive switch lead with a plastic band. Ê Clamp the gear motor and four-wheel drive switch lead and differential gear case breather hose. Ë Fasten the headlight lead with a plastic band.

–7–

CABLE ROUTING

SPEC

A Carburetor warmer lead B CDI magneto lead C Starter motor lead D Oil hose E Gear motor and four-wheel drive switch lead

1 Headlight lead 2 Fan motor lead 3 Final gear case breather hose 4 Main switch lead 5 Neutral indicator light, reverse indicator light, and meter light lead 6 Starter cable 7 Oil temperature warning light and four-wheel drive indicator light lead 8 Fuel tank breather hose 9 Air vent hose 0 Rear brake breather hose

È Pass the final gear case breather hose more than 50 mm (2.0 in) through the bracket. É Clamp the starter cable and final gear case breather hose with a plastic clamp. Ê Fasten the final gear case breather hose and carburetor warmer lead with a plastic clamp.

–8–

CABLE ROUTING

SPEC

C Speedometer cable D Reverse control cable E Starter motor lead F CDI magneto lead G Vacuum chamber breather hose

1 Carburetor warmer lead 2 Fuse box lead 3 Negative battery lead 4 Tail/brake light lead 5 Final gear case breather hose 6 Thermo unit lead 7 Carburetor overflow hose 8 Air vent hose 9 Rear brake breather hose 0 Wire harness A Gear position switch lead B Rear brake cable

È Clamp the wire harness and starter motor lead with a plastic clamp. É Clamp the wire harness and tail/brake lead light with a plastic clamp.

–9–

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 maintenance 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.

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 ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION: NOTE:

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.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:

This is a chapter with its symbol on the upper right of each page.

2nd title 2:

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3:

This is a final title.

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure 4 is placed between a line of asterisks “*” with each procedure preceded by “●”.

IMPORTANT FEATURES ● Data and a special tool are framed in a box preceded by a relevant symbol 5. ● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8. ● A condition of a faulty component will precede an arrow symbol 9 and the course of action will follow it.

EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

1

EB003000

2

GEN INFO

ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.

SPEC

3

4

CHK ADJ

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting

ENG

5

6

CARB

DRIV

7

8

CHAS

–

ELEC

+

0

Illustrated symbols 0 to F are used to identify the specifications appearing in the text.

A

B

0 Filling fluid A Lubricant B Special tool C Torque D Wear limit, clearance E Engine speed F Ω, V, A

C

D

9

TRBL SHTG

T.

R.

E

F

G

H

G

E J

K B

M

L

M M

LS

N

Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points.

I

S

O

LT

New

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 indicate where to apply a locking agent N and when to install a new part O. N Apply the locking agent (LOCTITE) O Replace

CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATIONS ........................................................ 2 ENGINE................................................................................................ 2 CHASSIS.............................................................................................. 3 ELECTRICAL ....................................................................................... 4 CABLE ROUTING .................................................................................... 5 PERIODIC CHECKS AND ADJUSTMENTS ................................................. 16 INTRODUCTION .................................................................................... 16 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ..................... 16 CHASSIS ................................................................................................ 18 ADJUSTING THE FRONT BRAKE .................................................... 18 ADJUSTING THE REAR BRAKE LIGHT SWITCH............................ 18 DRIVE TRAIN ................................................................................................. 19 CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ............. 19 ASSEMBLING THE DIFFERENTIAL GEAR ...................................... 21 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH .................................................... 22 ELECTRICAL ................................................................................................. 24 CHECKING THE SWITCH ..................................................................... 24 CHECKING THE SWITCH ................................................................. 24 CHECKING A SWITCH SHOWN IN THE MANUAL .......................... 24 IGNITION SYSTEM ................................................................................ 25 CIRCUIT DIAGRAM ........................................................................... 25 TROUBLESHOOTING ....................................................................... 26 ELECTRIC STARTING SYSTEM ........................................................... 31 CIRCUIT DIAGRAM ........................................................................... 31 TROUBLESHOOTING ....................................................................... 32 LIGHTING SYSTEM ............................................................................... 35 CIRCUIT DIAGRAM ........................................................................... 35 CHECKING THE LIGHTING SYSTEM .............................................. 36 SIGNAL SYSTEM ................................................................................... 37 CIRCUIT DIAGRAM ........................................................................... 37 TROUBLESHOOTING ....................................................................... 38 CHECKING THE SIGNAL SYSTEM .................................................. 40 2WD/4WD SELECTING SYSTEM ......................................................... 42 CIRCUIT DIAGRAM ........................................................................... 42 TROUBLESHOOTING ....................................................................... 43 YFM400FWNP WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Model

YFM400FWNP

Model code: Oil type or grade: Engine oil

5FUA (USA)

API service SE, SF, SG type or higher

Final gear oil Differential gear oil Differential gear case oil Periodic oil change Total amount Chassis: Frame type Caster angle Camber angle Kingpin angle Trail Tread (STD) Tread (STD) Toe-in Brake: Front brake Rear brake Bulb wattage × quantity: Headlight Tail/brake light Meter light Neutral indicator light Reverse indicator light Oil temperature warning light Four-wheel drive indicator light

SAE 80 API “GL-4” Hypoid gear oil SAE 80 API “GL-4” Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt) 0.4 L (0.35 Imp qt, 0.42 US qt)

front rear

type operation type operation

Steel tube frame 4° 1° 13° 21 mm (0.83 in) 860 mm (33.86 in) 820 mm (32.28 in) 5 ~ 15 mm (0.20 ~ 0.59 in) Dual disc brake Right hand operation Drum brake Left hand and right foot operation 12 V 30 W/30 W × 2 12 V 5 W/21 W × 1 12 V 3.4 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1

–1–

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Model

YFM400FWNP

Cylinder:

Bore size Out of round limit * Measuring point <Wear limit> Rocker arm/rocker arm shaft: Bearing inside diameter <Limit> Shaft outside diameter <Limit> Arm-to-shaft clearance <Limit> Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum

82.97 ~ 83.02 mm (3.267 ~ 3.269 in) 0.05 mm (0.0020 in) 40 mm (1.57 in) <83.15 mm (3.274 in)> 11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) <12.058 mm (0.4747 in)> 11.961 ~ 11.971 mm (0.4709 ~ 0.4713 in) <11.931 mm (0.4697 in)> 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) <0.08 mm (0.0031 in)>

(M.J.) (M.A.J.) (J.N.) (N.J.) (P.A.J.1) (P.A.J.2) (P.O.) (P.J.) (B.P.1) (B.P.2) (B.P.3) (V.S.) (G.S.1) (G.S.2) (Th.V.) (F.H.) (F.L.)

5FUA 12 #112.5 #70 5EP4-55-3 P-0M (#826) #80 1.3 0.8 #17.5 0.8 0.8 0.8 2.0 #70 0.9 #100 12 ~ 14 mm (0.47 ~ 0.55 in) 3 ~ 4 mm (0.12 ~ 0.16 in) 1,450 ~ 1,550 r/min 33.3 kPa (250 mmHg, 10 inHg)

–2–

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS Model Front suspension: Shock absorber travel Fork spring free length Spring rate (K1) Stroke (K1) Optional spring Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate (K1) Stroke (K1) Optional spring Brake lever & brake pedal: Brake lever free play (at lever end) Brake lever free play (left) Brake pedal position Brake pedal free play Throttle lever free play

YFM400FWNP 102 mm (4.02 in) 318.4 mm (12.5 in) 12.3 N/mm (1.25 kg/mm, 70.2 lb/in) 0 ~ 102 mm (0.00 ~ 4.02 in) No 100 mm (3.94 in) 296 mm (11.7 in) 253 mm (9.96 in) 30.4 N/mm (3.10 kg/mm, 174 lb/in) 0 ~ 100 mm (0.00 ~ 3.94 in) No 0 mm (0 in) 5 ~ 8 mm (0.20 ~ 0.31 in) 5 mm (0.2 in) 20 ~ 30 mm (0.8 ~ 1.2 in) 3 ~ 5 mm (0.1 ~ 0.2 in)

Tightening torques Part to be tightened

Thread size

Engine stay (front-upper) and frame Engine stay (front-lower) and frame Engine stay (front-upper) and engine Engine stay (front-lower) and engine Engine and frame (rear-upper) Engine and frame (rear-under) Differential gear case and frame Steering knuckle and front arm

M8 M8 M8 M10 M10 M10 M10 M12

–3–

Tightening torque Nm

m·kg

ft·lb

34 34 34 69 69 69 64 30

3.4 3.4 3.4 6.9 6.9 6.9 6.4 3.0

24 24 24 50 50 50 46 22

Remarks

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL Model

10° at 1,000 r/min 33° at 5,000 r/min Digital type

Ignition timing (B.T.D.C.)

Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type

YFM400FWNP

Engine speed (× 10³ r/min)

C.D.I.: Magneto model/manufacturer Pickup coil resistance/color C.D.I. unit model/manufacturer Rectifier: Regulator type Model/manufacturer No load regulated voltage Capacity Withstand voltage Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Reserve fuse

F4T423/MITSUBISHI 459 ~ 561 Ω at 20 °C (68 °F)/White/Red – White/Green F8T38673/MITSUBISHI Semi conductor-short circuit SH640E-11/SHINDENGEN 14.1 ~ 14.9 V 14 A 200 V Fuse 30 A × 1 15 A × 1 10 A × 1 10 A × 1 10 A × 1 30 A × 1 15 A × 1 10 A × 1

–4–

CABLE ROUTING

SPEC

CABLE ROUTING È Fasten the front brake light switch lead and the on-command four-wheel drive switch lead with a plastic band. É Fasten the starter cable, rear brake lever switch lead, and handlebar switch (left) lead with a plastic band.

1 Rear brake cable 2 Starter cable 3 Front brake hose 4 Front brake light switch lead 5 On-command four-wheel drive switch lead 6 Throttle cable 7 Fuel tank breather hose 8 Rear brake lever switch lead 9 Handlebar switch (left) lead

–5–

CABLE ROUTING

SPEC

A Headlight lead B Gear motor and four-wheel drive switch lead C Differential gear case breather hose D Auxiliary DC jack connector E Speedometer cable F Front brake hose

1 Throttle cable 2 Reverse control cable 3 Rear brake cable 4 Handlebar switch (left) lead 5 Starter cable 6 Neutral indicator light, reverse indicator light, and meter light lead 7 Rear brake lever switch lead 8 Oil temperature warning light and four-wheel drive indicator light lead 9 Main switch lead 0 Fan motor lead

â&#x20AC;&#x201C;6â&#x20AC;&#x201C;

CABLE ROUTING

SPEC

È Fasten the headlight lead and fan motor lead with a plastic band. É Fasten the gear motor and four-wheel drive switch lead with a plastic band. Ê Clamp the gear motor and four-wheel drive switch lead and differential gear case breather hose. Ë Fasten the headlight lead with a plastic band.

–7–

CABLE ROUTING

SPEC

A Carburetor warmer lead B CDI magneto lead C Starter motor lead D Oil hose E Gear motor and four-wheel drive switch lead

1 Headlight lead 2 Fan motor lead 3 Final gear case breather hose 4 Main switch lead 5 Neutral indicator light, reverse indicator light, and meter light lead 6 Starter cable 7 Oil temperature warning light and four-wheel drive indicator light lead 8 Fuel tank breather hose 9 Air vent hose 0 Rear brake breather hose

È Pass the final gear case breather hose more than 50 mm (2.0 in) through the bracket. É Clamp the starter cable and final gear case breather hose with a plastic clamp. Ê Fasten the final gear case breather hose and carburetor warmer lead with a plastic clamp.

–8–

CABLE ROUTING

SPEC

C Speedometer cable D Reverse control cable E Starter motor lead F CDI magneto lead G Vacuum chamber breather hose

1 Carburetor warmer lead 2 Fuse box lead 3 Negative battery lead 4 Tail/brake light lead 5 Final gear case breather hose 6 Thermo unit lead 7 Carburetor overflow hose 8 Air vent hose 9 Rear brake breather hose 0 Wire harness A Gear position switch lead B Rear brake cable

È Clamp the wire harness and starter motor lead with a plastic clamp. É Clamp the wire harness and tail/brake lead light with a plastic clamp.

–9–

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