YFM4FAR

YFM400FAR

5TE2-AE1

SERVICE MANUAL

YFM4FAR/YFM400FAR

SERVICE MANUAL

©2002 by Yamaha Motor Co., Ltd.

First edition, April 2002

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 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!

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 symbols”)

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 checks 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 lithium-soap-based grease

N Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded

diagrams indicate where to apply a locking

agent O and when to install a new part P.

O Apply the locking agent (LOCTITE^®)

P Replace

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARB

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO 1

SPECIFICATIONS

SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ 3

ENGINE

ENG 4

COOLING SYSTEM

COOL 5

CARBURETION

CARB 6

DRIVE TRAIN

DRIV 7

CHASSIS

CHAS 8

ELECTRICAL

ELEC 9

TROUBLESHOOTING

TRBL

SHTG 10

–

+

GEN

INFO 1

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION ........................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ................................................. 1-1

MODEL LABEL ..................................................................................... 1-1

IMPORTANT INFORMATION ...................................................................... 1-2

PREPARATION FOR REMOVAL PROCEDURES ............................... 1-2

REPLACEMENT PARTS ...................................................................... 1-2

GASKETS, OIL SEALS AND O-RINGS ................................................ 1-2

LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-3

BEARINGS AND OIL SEALS ................................................................ 1-3

CIRCLIPS .............................................................................................. 1-3

CHECKING OF CONNECTIONS ................................................................. 1-4

SPECIAL TOOLS ......................................................................................... 1-5

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.

1 - 2

GEN

INFO

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL

PROCEDURES

1.Remove all dirt, mud, dust and foreign

material before removal and disassembly.

2.Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.

3.When disassembling the machine, always

keep mated parts together. This includes

gears, cylinder, piston and other parts that

have been “mated” through normal wear.

Mated parts must always be reused or

replaced as an assembly.

4.During machine disassembly, clean all parts

and place them in trays in the order of

disassembly. This will speed up assembly

and allow for the correct installation of all

parts.

5.Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all

replacements.

Use

oil

and

grease

recommended by Yamaha for all lubrication

jobs. Other brands may be similar in function

and appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1.Replace all gaskets, seals and O-rings when

overhauling the engine. All gasket surfaces,

oil seal lips and O-rings must be cleaned.

2.Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil

seal lips.

IMPORTANT INFORMATION

1 - 3

GEN

INFO

EB101030

LOCK WASHERS/PLATES AND COTTER

PINS

1.Replace all lock washers/plates 1 and cotter

pins after removal. Bend lock tabs along the

bolt or nut flats after the bolt or nut has been

tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1.Install bearings and oil seals so that the

manufacturer’s marks or numbers are visible.

When installing oil seals, apply a light

coating of lightweight lithium base grease to

the seal lips. Oil bearings liberally when

installing, if appropriate.

1 Oil seal

CAUTION:

Do not use compressed air to spin the

bearings dry. This will damage the bearing

surfaces.

1 Bearing

EB101050

CIRCLIPS

1.Check

all

circlips

carefully

before

reassembly. Always replace piston pin clips

after one use. Replace distorted circlips.

When installing a circlip 1, make sure that

the sharp-edged corner 2 is positioned

opposite the thrust 3 it receives. See

sectional view.

4 Shaft

IMPORTANT INFORMATION

1 - 4

GEN

INFO

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check

the

connectors

for

stains,

rust,

moisture, etc.

1.Disconnect:

G Connector

2.Check:

G Connector

Moisture → Dry each terminal with an air

blower.

Stains/rust → Connect and disconnect the

terminals several times.

3.Check:

G Connector leads

Looseness → Bend up the pin 1 and

connect the terminals.

4.Connect:

G Connector terminals

NOTE:

The two terminals “click” together.

5.Check:

G Continuity (using a pocket tester)

NOTE:

G If there is no continuity, clean the terminals.

G When checking the wire harness be sure to

perform steps 1 to 3.

G As a quick remedy, use a contact revitalizer

available at most part stores.

G Check the connector with a pocket tester as

shown.