YFM4FAT

YFM400FAT

5TE2-AE2

SUPPLEMENTARY

SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YFM4FAT/YFM400FAT. For complete service information procedures it is necessary to use this

Supplementary Service Manual together with the following manual.

YFM4FAR/YFM400FAR SERVICE MANUAL: 5TE2-AE1

YFM4FAT/YFM400FAT

SUPPLEMENTARY

SERVICE MANUAL

©2004 by Yamaha Motor Co., Ltd.

First edition, June 2004

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

CONTENTS

SPECIFICATIONS ............................................................................................1

GENERAL SPECIFICATIONS ..................................................................1

MAINTENANCE SPECIFICATIONS .........................................................3

ENGINE ................................................................................................3

CHASSIS ..............................................................................................4

ELECTRICAL ........................................................................................6

CABLE ROUTING .....................................................................................7

PERIODIC CHECKS AND ADJUSTMENTS ..................................................18

INTRODUCTION .....................................................................................18

PERIODIC MAINTENANCE/LUBRICATION ...........................................18

SEAT, CARRIERS, FENDERS AND FUEL TANK ..................................20

FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ..........20

CHASSIS .................................................................................................22

ADJUSTING THE REAR BRAKE .......................................................22

CHECKING THE BRAKE FLUID LEVEL ............................................24

CHECKING THE REAR BRAKE PADS ..............................................25

CHECKING THE BRAKE HOSES ......................................................25

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...............................26

ADJUSTING THE SELECT LEVER CONTROL CABLE

AND SHIFT ROD ................................................................................27

CHECKING THE FINAL GEAR OIL LEVEL ........................................29

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ......29

ADJUSTING THE REAR SHOCK ABSORBERS ...............................30

ENGINE ..........................................................................................................31

CRANKCASE ..........................................................................................31

STARTER MOTOR, TIMING CHAIN AND OIL FILTER .....................31

CRANKCASE ......................................................................................34

INSTALLING THE SHIFT LEVER .......................................................35

TRANSMISSION .....................................................................................36

CHECKING THE STOPPER LEVER AND STOPPER WHEEL .........38

MIDDLE GEAR ........................................................................................39

MIDDLE DRIVEN SHAFT ...................................................................39

DRIVE TRAIN .................................................................................................41

TROUBLESHOOTING ............................................................................41

FRONT CONSTANT VELOCITY JOINTS

AND DIFFERENTIAL GEAR ..................................................................44

MEASURING AND ADJUSTING THE DIFFERENTIAL

GEAR LASH ........................................................................................44

REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR

AND DRIVE SHAFT ...............................................................................46

ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS ............51

DISASSEMBLING THE FINAL DRIVE GEAR ....................................52

CHECKING THE DRIVE SHAFT/UNIVERSAL JOINT YOKE ............52

CHECKING THE FINAL DRIVE GEAR ...............................................53

REPLACING THE FINAL DRIVE ROLLER BEARING .......................53

REPLACING THE FINAL DRIVE PINION GEAR AND BEARING ......54

POSITIONING THE FINAL DRIVE PINION GEAR .............................56

MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH .........57

ASSEMBLING THE FINAL DRIVE GEAR ..........................................60

CHASSIS ........................................................................................................62

FRONT AND REAR WHEELS ................................................................62

REAR WHEELS ..................................................................................62

INSTALLING THE REAR BRAKE DISC .............................................64

INSTALLING THE REAR WHEEL HUBS ...........................................64

REAR BRAKE .........................................................................................65

REAR BRAKE PADS ..........................................................................65

REPLACING THE REAR BRAKE PADS ............................................66

REAR BRAKE MASTER CYLINDER ..................................................68

CHECKING THE MASTER CYLINDER ..............................................71

ASSEMBLING THE REAR BRAKE MASTER CYLINDER .................71

INSTALLING THE REAR BRAKE MASTER CYLINDER ....................72

REAR BRAKE CALIPER .....................................................................74

DISASSEMBLING THE REAR BRAKE CALIPER ..............................76

CHECKING THE REAR BRAKE CALIPER ........................................76

ASSEMBLING THE REAR BRAKE CALIPER ....................................77

INSTALLING THE REAR BRAKE CALIPER ......................................78

STEERING SYSTEM ..............................................................................80

STEERING STEM ...............................................................................80

FRONT ARMS AND FRONT SHOCK ABSORBERS .............................82

REAR KNUCKLES AND STABILIZER ....................................................84

CHECKING THE REAR KNUCKLES ..................................................85

CHECKING THE STABILIZER ...........................................................85

REAR ARMS AND REAR SHOCK ABSORBERS ..................................86

CHECKING THE REAR ARMS ...........................................................87

INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS ....87

ELECTRICAL .................................................................................................88

ELECTRICAL COMPONENTS ...............................................................88

CHECKING THE SWITCHES .................................................................89

CHECKING THE SWITCH CONTINUITY ...........................................89

SIGNAL SYSTEM ...................................................................................91

CIRCUIT DIAGRAM ............................................................................91

CHECKING THE SIGNAL SYSTEM ...................................................93

YFM4FAT/YFM400FAT WIRING DIAGRAM

– 1 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

1P11, 1P14 (for USA)

1P12 (for CDN)

1P13 (for Oceania)

Dimensions:

Overall length

1,993 mm (78.5 in)

Overall width

1,093 mm (43.0 in)

Overall height

1,120 mm (44.1 in)

Seat height

830 mm (32.7 in)

Wheelbase

1,233 mm (48.5 in)

Minimum ground clearance

245 mm (9.7 in)

Minimum turning radius

3,000 mm (118.1 in)

Basic weight:

With oil and full fuel tank

279 kg (615 lb) (for USA and CDN)

283 kg (624 lb) (for Oceania)

Oil capacity:

Engine oil

Periodic oil change

2.30 L (2.02 Imp qt, 2.43 US qt)

With oil filter replacement

2.40 L (2.11 Imp qt, 2.54 US qt)

Total amount

2.60 L (2.29 Imp qt, 2.75 US qt)

Final gear case oil

Periodic oil change

0.16 L (0.14 Imp qt, 0.17 US qt)

Total amount

0.18 L (0.16 Imp qt, 0.19 US qt)

Differential gear case oil

Periodic oil change

0.35 L (0.31 Imp qt, 0.37 US qt)

Total amount

0.40 L (0.35 Imp qt, 0.42 US qt)

Radiator capacity (including all routes)

1.32 L (1.16 Imp qt, 1.40 US qt)

Chassis:

Frame type

Steel tube frame

Caster angle

2.5°

Camber angle

1°

Kingpin angle

11°

Kingpin offset

0 mm (0 in)

Trail

8.5 mm (0.33 in)

Tread (STD)

front

850 mm (33.46 in)

rear

839 mm (33.03 in)

Toe-in

0 ~ 10 mm (0 ~ 0.39 in)

GENERAL SPECIFICATIONS

– 2 –

SPEC

GENERAL SPECIFICATIONS

Tires:

Type

Tubeless

Size

front

AT25 × 8–12

rear

AT25 × 10–12

Manufacturer

front

MAXXIS (for USA and CDN)

CHENG SHIN (for Oceania)

rear

MAXXIS (for USA and CDN)

CHENG SHIN (for Oceania)

Model

front

M911Y (for USA and CDN)

C828 (for Oceania)

rear

M912Y (for USA and CDN)

C828 (for Oceania)

Brakes:

Front brake

type

Dual disc brake

operation

Right hand operation

Rear brake

type

Single disc brake

operation

Left hand and right foot operation

Suspension:

Front suspension

Double wishbone

Rear suspension

Double wishbone

Bulb wattage × quantity:

Headlight

12 V 30 W/30 W × 2

Tail/brake light

12 V 5 W/21 W × 1

Meter light

14 V 3 W × 1

Indicator lights

Neutral

12 V 1.7 W × 1

Reverse

12 V 1.7 W × 1

Park

12 V 1.7 W × 1

Coolant temperature

12 V 1.7 W × 1

Four-wheel drive

12 V 1.7 W × 1

Item

Standard

– 3 –

SPEC

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Tightening torques

Item

Standard

Limit

Carburetor:

I. D. mark

5TEC 00

----

Main jet

(M.J)

#132.5

----

Main air jet

(M.A.J)

#50

----

Jet needle

(J.N)

5EP13-55-3

----

Needle jet

(N.J)

P-0M

----

Pilot air jet

(P.A.J.1)

#80

----

Pilot air jet

(P.A.J.2)

1.3

----

Pilot outlet

(P.O)

0.95

----

Pilot jet

(P.J)

#17.5

----

Bypass 1

(B.P.1)

0.8

----

Bypass 2

(B.P.2)

0.8

----

Bypass 3

(B.P.3)

0.8

----

Pilot screw

(P.S.)

2-1/2 turns out

----

Valve seat size

(V.S)

2.0

----

Starter jet

(G.S.1)

#75

----

Starter jet

(G.S.2)

0.9

----

Throttle valve size

(Th.V)

#90

----

Float height

(F.H)

13 mm (0.51 in)

----

Fuel level

(F.L)

4.0 ~ 5.0 mm (0.16 ~ 0.20 in)

----

Engine idle speed

1,450 ~ 1,550 r/min

----

Intake vacuum

33.3 kPa (250 mmHg, 9.84 inHg)

----

Part to be tightened

Part

name

Thread

size

Q’ty

Tightening torque

Remarks

Nm

m · kg ft · lb

Shift lever 2 assembly

Bolt

M6

1

14

1.4

10

Shift lever cover

Bolt

M6

4

10

1.0

7.2

Stopper lever

Bolt

M6

1

10

1.0

7.2

Stopper lever shaft

Bolt

M6

1

10

1.0

7.2

Park switch

—

M10

1

20

2.0

14

– 4 –

SPEC

MAINTENANCE SPECIFICATIONS

CHASSIS

Item

Standard

Limit

Front suspension:

Shock absorber travel

99 mm (3.90 in)

----

Spring free length

285 mm (11.22 in)

----

Spring fitting length

231.9 mm (9.13 in)

----

Spring rate

(K1)

15 N/mm

(1.53 kg/mm, 85.68 lb/in)

----

Stroke

(K1)

0 ~ 99 mm (0 ~ 3.90 in)

----

Optional spring

No

----

Rear suspension:

Shock absorber travel

95 mm (3.74 in)

----

Spring free length

277.9 mm (10.94 in)

----

Spring fitting length

247.9 mm (9.76 in)

----

Spring rate

(K1)

27 N/mm

(2.75 kg/mm, 153.99 lb/in)

----

Stroke

(K1)

0 ~ 95 mm (0 ~ 3.74 in)

----

Optional spring

No

----

Rear disc brake:

Type

Single

----

Disc outside diameter × thickness

220.0 × 3.5 mm (8.66 ~ 0.14 in)

----

Pad thickness

inner

5.0 mm (0.20 in)

1 mm

(0.04 in)

Pad thickness

outer

5.0 mm (0.20 in)

1 mm

(0.04 in)

Master cylinder inside diameter

14 mm (0.55 in)

----

Caliper cylinder inside diameter

32.03 mm (1.26 in)

----

Brake fluid type

DOT 4

----

Brake lever and brake pedal:

Brake lever free play (pivot)

front

0 mm (0 in)

----

rear

0.5 ~ 2.0 mm (0.02 ~ 0.08 in)

----

Brake pedal height

67 ~ 77 mm (2.64 ~ 3.03 in)

----

Throttle lever free play

3 ~ 5 mm (0.12 ~ 0.20 in)

----

– 5 –

SPEC

MAINTENANCE SPECIFICATIONS

Tightening torques

Part to be tightened

Thread

size

Tightening torque

Remarks

Nm

m · kg ft · lb

Rear shock absorber and sub-frame

M10

45

4.5

32

Rear shock absorber and rear lower arm

M10

45

4.5

32

Rear upper arm and sub-frame

M10

45

4.5

32

LS

Rear lower arm and sub-frame

M10

45

4.5

32

LS

Rear upper arm and rear knuckle

M10

45

4.5

32

Rear lower arm and rear knuckle

M10

45

4.5

32

Stabilizer and sub-frame

M8

30

3.0

22

Stabilizer joint and stabilizer

M10

56

5.6

40

Stabilizer joint and rear lower arm

M10

56

5.6

40

Frame and sub-frame (front lower)

M12

82

8.2

59

Frame and sub-frame (rear upper)

M10

48

4.8

35

Final drive gear case and sub-frame

M10

45

4.5

32

Trailer hitch and sub-frame

M10

40

4.0

29

Brake disc guard and steering knuckle

M6

7

0.7

5.1

Front lower arm and protector

M6

7

0.7

5.1

Steering stem, pitman arm and frame

M14

190

19.0

140

Fuel tank and frame

M6

10

1.0

7.2

Front wheel and wheel hub

M10

55

5.5

40

Rear axle and wheel hub

M20

260

26.0

190

Stake

Rear knuckle and brake caliper

M8

30

3.0

22

Brake disc guard and rear knuckle

M6

7

0.7

5.1

Rear brake disc and wheel hub

M8

30

3.0

22

LT

Front brake pipe joint and frame

M6

7

0.7

5.1

Brake hose holder and steering knuckle

M6

7

0.7

5.1

Brake hose holder and front upper arm

M6

7

0.7

5.1

Rear brake hose union bolt

M10

30

3.0

22

Rear brake pad holding bolt

M10

17

1.7

12

LT

Rear brake master cylinder

M8

23

2.3

17

Rear brake master cylinder bracket

M8

30

3.0

22

Rear brake master cylinder cover

M6

7

0.7

5.1

Rear brake pipe nut

M10

19

1.9

13

Rear brake pipe joint and frame

M6

7

0.7

5.1

Final drive gear case filler bolt

M14

23

2.3

17

Final drive gear case drain bolt

M14

23

2.3

17

Final drive gear case and bearing housing

M10

40

4.0

29

Final drive gear case and bearing housing

M8

23

2.3

17

Bearing retainer (final drive pinion gear)

M75

115

11.5

85

Left-hand

threads

Universal joint yoke (final drive pinion gear)

M14

97

9.7

70

Ring gear stopper

M8

16

1.6

11

Air duct assembly 1 and frame

M6

7

0.7

5.1

Engine skid plate and frame

M6

7

0.7

5.1

Final gear case skid plate and sub-frame

M6

7

0.7

5.1

– 6 –

SPEC

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item

Standard

Limit

C.D.I.:

Magneto model/manufacturer

F4T464/MITSUBISHI

----

Pickup coil resistance/color

459 ~ 561 Ω at 20 °C (68 °F)/

White/Red – White/Green

----

Rotor rotation direction sensing coil resis-

tance/color

0.086 ~ 0.105 Ω at 20 °C (68 °F)/

Red – White/Blue

----

C.D.I. unit model/manufacturer

F8T40376/MITSUBISHI

----

– 7 –

SPEC

CABLE ROUTING

CABLE ROUTING

1 Rear brake switch lead

2 Starter cable

3 Rear brake cable

4 Front brake hose

5 On-command four-wheel drive switch

6 Throttle cable

7 Horn switch (for Oceania)

8 Handlebar switch

9 Handlebar switch lead

0 Main switch lead

A Fan motor lead

B Fan motor breather hose

C Differential gear case breather hose

D Sub-wire harness

E Horn switch lead (for Oceania)

F On-command four-wheel drive switch lead

G Coolant reservoir hose

H Coolant reservoir breather hose