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Yamaha 5TE-F8197-10 Camper User Manual

User manual for the device Yamaha 5TE-F8197-10 Camper

Yamaha 5TE-F8197-10 Camper User Manual

Extracts of contents

Content summary on the page No. 1

YFM400FARSERVICE MANUALLIT-11616-16-025TE-F8197-10

Content summary on the page No. 2

YFM400FARSERVICE MANUAL©2002 by Yamaha Motor Corporation, U.S.A.First Edition, April 2002All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Corporation, U.S.A.is expressly prohibited.Printed in U.S.A.LIT-11616-16-02

Content summary on the page No. 3

EB001000NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in onemanual, so it is assumed that anyone who uses this book to perform maintenance and repairs onYamaha machine has a basic understanding of the mechanical ideas and the procedures ofmachine repair. Repairs attempted by anyone without this knowledge are likely to render themachine unsafe and unfit for

Content summary on the page No. 4

EB002000HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis 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 eachsection. 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 proce

Content summary on the page No. 5

1EB0030002GENINFOILLUSTRATED SYMBOLSIllustrated symbols 1 to 0 are printed on thetop right of each page and indicate the subjectof each chapter.SPEC34CHKADJ1 General information2 Specifications3 Periodic checks and adjustments4 Engine5 Cooling system6 Carburetion7 Drive train8 Chassis9 Electrical0 TroubleshootingENG56COOLCARB78CHASDRIV90–ELECTRBLSHTG+AIllustrated symbols A to H are used to identifythe specifications appearing in the text.BCDEFA Can be serviced with engine mountedB Filling flui

Content summary on the page No. 6

TABLE OF CONTENTSGENERAL INFORMATIONSPECIFICATIONSPERIODIC CHECKS ANDADJUSTMENTSENGINECOOLING SYSTEMCARBURETIONDRIVE TRAINCHASSISGENINFO1SPEC2CHKADJ3ENG4COOL5CARB6DRIV7CHAS8–ELECTRICALTROUBLESHOOTING+ELEC9TRBLSHTG10

Content summary on the page No. 7

CONTENTSCHAPTER 1.GENERAL INFORMATIONMACHINE IDENTIFICATION ........................................................................ 1-1VEHICLE IDENTIFICATION NUMBER ................................................. 1-1MODEL LABEL ...................................................................................... 1-1IMPORTANT INFORMATION ....................................................................... 1-2PREPARATION FOR REMOVAL PROCEDURES ............................... 1-2REPLACEMENT

Content summary on the page No. 8

CHAPTER 3.PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION ........................................................................................... 3-1PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1SEAT, CARRIERS, FENDERS AND FUEL TANK ....................................... 3-3SEAT AND SIDE PANELS .................................................................... 3-3FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ............. 3-4REAR CARRIER AND REAR FENDER .

Content summary on the page No. 9

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ...... 3-46CHECKING THE STEERING SYSTEM .............................................. 3-47ADJUSTING THE TOE-IN ................................................................... 3-47ADJUSTING THE FRONT SHOCK ABSORBERS ............................. 3-49ADJUSTING THE REAR SHOCK ABSORBER .................................. 3-49CHECKING THE TIRES ...................................................................... 3-49CHECKING THE WHEELS ...........

Content summary on the page No. 10

CYLINDER AND PISTON ........................................................................... 4-27REMOVING THE PISTON .................................................................. 4-28CHECKING THE TIMING CHAIN GUIDE ........................................... 4-28CHECKING THE CYLINDER AND PISTON ....................................... 4-28CHECKING THE PISTON RINGS ....................................................... 4-30CHECKING THE PISTON PIN ..........................................

Content summary on the page No. 11

CRANKSHAFT AND OIL PUMP ................................................................ 4-65OIL PUMP ........................................................................................... 4-66REMOVING THE CRANKSHAFT ....................................................... 4-67CHECKING THE OIL PUMP ............................................................... 4-67CHECKING THE CRANKSHAFT ........................................................ 4-68INSTALLING THE CRANKSHAFT AND BALANCER ....

Content summary on the page No. 12

CHAPTER 6.CARBURETIONCARBURETOR ............................................................................................. 6-1DISASSEMBLING THE CARBURETOR ............................................... 6-4CHECKING THE CARBURETOR ......................................................... 6-4ASSEMBLING THE CARBURETOR ..................................................... 6-6ADJUSTING THE FUEL LEVEL ............................................................ 6-7CHAPTER 7.DRIVE TRAINTROUBLESHOOTI

Content summary on the page No. 13

CHAPTER 8.CHASSISFRONT AND REAR WHEELS ...................................................................... 8-1FRONT WHEELS .................................................................................. 8-1REAR WHEELS .................................................................................... 8-2CHECKING THE WHEELS ................................................................... 8-3CHECKING THE WHEEL HUBS ........................................................... 8-3CHECKING T

Content summary on the page No. 14

FRONT ARMS AND FRONT SHOCK ABSORBERS ................................ 8-40REMOVING THE FRONT ARMS ........................................................ 8-42CHECKING THE FRONT ARMS ......................................................... 8-42CHECKING THE FRONT SHOCK ABSORBER ................................. 8-44INSTALLING THE FRONT ARMS ANDFRONT SHOCK ABSORBER .......................................................... 8-45REAR SHOCK ABSORBER AND SWINGARM .....................................

Content summary on the page No. 15

LIGHTING SYSTEM .................................................................................... 9-25CIRCUIT DIAGRAM ............................................................................ 9-25TROUBLESHOOTING ........................................................................ 9-26CHECKING THE LIGHTING SYSTEM ................................................ 9-28SIGNAL SYSTEM ....................................................................................... 9-32CIRCUIT DIAGRAM .

Content summary on the page No. 16

OVERHEATING .......................................................................................... 10-5OVERHEATING .................................................................................. 10-5FAULTY BRAKE ......................................................................................... 10-5POOR BRAKING EFFECT .................................................................. 10-5SHOCK ABSORBER MALFUNCTION ....................................................... 10-6MALFUNCTI

Content summary on the page No. 17

MACHINE IDENTIFICATIONGENINFOGENERAL INFORMATIONMACHINE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1stamped into the left side of the frame.isMODEL LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spareparts.1-1

Content summary on the page No. 18

IMPORTANT INFORMATIONGENINFOEB101000IMPORTANT INFORMATIONPREPARATION FOR REMOVALPROCEDURES1.Remove all dirt, mud, dust and foreignmaterial before removal and disassembly.2.Use proper tools and cleaning equipment.Refer to the “SPECIAL TOOLS” section.3.When disassembling the machine, alwayskeep mated parts together. This includesgears, cylinder, piston and other parts thathave been “mated” through normal wear.Mated parts must always be reused orreplaced as an assembly.4.During machine disa

Content summary on the page No. 19

IMPORTANT INFORMATIONGENINFOEB101030LOCK WASHERS/PLATES AND COTTERPINS1.Replace all lock washers/plates 1 and cotterpins after removal. Bend lock tabs along thebolt or nut flats after the bolt or nut has beentightened to specification.EB101040BEARINGS AND OIL SEALS1.Install bearings and oil seals so that themanufacturer’s marks or numbers are visible.When installing oil seals, apply a lightcoating of lightweight lithium base grease tothe seal lips. Oil bearings liberally wheninstalling, if app

Content summary on the page No. 20

CHECKING OF CONNECTIONSGENINFOEB801000CHECKING OF CONNECTIONSCheck the connectorsmoisture, etc.forstains,rust,1.Disconnect:● Connector2.Check:● ConnectorMoisture → Dry each terminal with an airblower.Stains/rust → Connect and disconnect theterminals several times.3.Check:● Connector leadsLooseness → Bend up the pin 1 andconnect the terminals.4.Connect:● Connector terminalsNOTE:The two terminals “click” together.5.Check:● Continuity (using a pocket tester)NOTE:● If there is

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