1993-1999 Yamaha YFM400FW ATV Service Manual

Description

This Official 1993-1999 Yamaha YFM400FW Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for:

1993 YFM400FW Kodiak 4WD ATV models
1994 YFM400FW Kodiak 4WD ATV models
1995 YFM400FW Kodiak 4WD ATV models
1996 YFM400FW Kodiak 4WD ATV models
1997 YFM400FW Kodiak 4WD ATV models
1998 YFM400FW Kodiak 4WD ATV models
1999 YFM400FW Kodiak 4WD ATV models

Table of Contents

General Information
Specifications
Periodic Inspection And Adjustment
Engine Overhaul
Carburetion
Drive Train
Chassis
Electrical
Troubleshooting

Index of Topics

Chapter 1 General Information
Machine Identification
Vehicle Identification Number (for USA And CDN)
Frame Serial Number (except For USA And CDN)
Engine Serial Number
Important Information
Preparation For Removal
All Replacement Parts
Gaskets, Oil Seals, And O-rings
Lock Washers/plates And Cotter Pins
Bearings And Oil Seals
Circlips
Special Tools
Fortune Up
For Engine Service
For Drive Train Service
For Chassis Service
For Electrical Components

Chapter 2 Specifications
General Specifications
Maintenance Specifications
Engine
Chassis
Electrical
Exclusive Specifications
General Torque Specifications
Lubrication Points And Lubricant Type
Engine
Chassis
Lubrication Diagrams
Cable Routing

Chapter 3 Periodic Inspections And Adjustment
Introduction
Periodic Maintenance/lubrication
Seat, Carriers, Fenders And Fuel Tank
Removal
Installation
Engine
Valve Clearance Adjustment
Timing Chain Adjustment
Idling Speed Adjustment
Throttle Cable Free Play Adjustment
Speed Limiter Adjustment
Spark Plug Inspection
Ignition Timing Check
Compression Pressure Measurement
Engine Oil/transfer Gear Oil Level Inspection
“Oil Temp” Indicator Light Check
Engine Oil/transfer Gear Oil Replacement
Oil Pressure Inspection
Clutch Adjustment
Air Filter Cleaning
Chassis
Front Brake Adjustment
Rear Brake Lever And Pedal Adjustment
Front Brake Fluid Level Inspection
Air Bleeding (front Brake System)
Front Brake Lining Inspection
Rear Brake Shoe Inspection
Select Lever Control Cable Adjustment
Final Gear Oil Level Inspection
Final Gear Oil Replacement
Differential Gear Oil Level Inspection
Differential Gear Oil Replacement
Constant Velocity Joint Dust Boot Inspection
Steering System Inspection
Toe-in Adjustment
Front And Rear Shock Absorbers Inspection
Front Shock Absorber Adjustment
Rear Shock Absorber Adjustment
Tires Inspection
Wheel Inspection
Cable Inspection And Lubrication
Levers, Pedal, Etc Lubrication
Electrical
Battery Inspection
Fuse Inspection
Headlight Beam Adjustment
Headlight Bulb Replacement

Chapter 4 Engine Overhaul
Engine Removal
Preparation For Removal
Engine Guards
Engine Oil And Transfer Gear Oil
Seat, Carriers, Fenders And Fuel Tank
Battery Lead
Select Lever
Exhaust Pipe And Muffler
Rear Brake Cable, Rod And Select Lever Cables
Wiring And Hose
Starter Motor
Carburetor
Oil Filter
Rear Drive Assembly And Swingarm
Transfer Gear Assembly And Front Drive Shaft
Engine Removal
Engine Disassembly
Recoil Starter
Cylinder Head And Cylinder
Piston
Crankcase Cover (left)
CDI Rotor
Cam Chain And Oil Pipe
Crankcase Cover (right)
Clutch
Balancer Drive And Driven Gears
Oil Pump And Shifter
Crankcase
Transmission, Middle Drive Axle And Crankshaft
Camshaft, Rocker Arm And Valve
Inspection And Repair
Cylinder Head
Valve Seat
Valve And Valve Guide
Valve Spring
Camshaft
Rocker Arm And Rocker Arm Shaft
Cam Chain Tensioner
Piston Ring
Piston Pin
Crankshaft
Balancer Drive Gear And Driven Gear
Primary Gears
Primary Clutch
Secondary Clutch
Oil Pump
Shifter And Transmission
Middle Gear
Starter
Starter Pulley And Recoil Starter
Balancer Drive Gear
Oil Strainer, Oil Filter And Oil Pipes
Crankcase
Bearings And Oil Seals
Circlips And Washers
Engine Assembly And Adjustment
Valve, Camshaft And Rocker Arm
Crankshaft, Middle Drive Axle Transmission And
Crankcase
Shifter And Oil Pump
Balancer Drive And Driven Gears
Clutch
Crankcase Cover (right), Shift Guide And Oil Pipe
Crankcase Cover (right)
Oil Pipe
CDI Rotor And Crankcase Cover (left)
Piston, Cylinder And Cylinder Head
Recoil Starter
Remounting Engine

Chapter 5 Carburetion
Carburetor
Removal
Disassembly
Inspection
Assembly
Installation
Fuel Level Adjustment

Chapter 6 Drive Train
Troubleshooting
Differential Gear And Constant Velocity Joints
Removal
Disassembly
Inspection
Measurement And Adjustment
Differential Gear Operation Check
Assembly
Installation
Transfer Gear
Removal
Disassembly
Inspection
Middle Drive And Driven Gear Shim Selection
Assembly
Adjustment
Installation
Rear Axle/rear Final Gear And Rear Drive Shaft
Removal
Disassembly
Inspection
Final Drive Pinion Gear And Ring Gear Shim Selectiois Assembly
Final Gear Gear Lash Measurement And Adjustmen1 Installation

Chapter 7 Chassis
Front And Rear Wheels
Removal
Inspection
Installation
Front Brake
Removal And Disassembly
Inspection And Repair
Assembly
Rear Brake
Removal
Inspection
Installation
Steering System
Removal
Inspection
Installation
Steering Knuckles And Tie-rod Ends
Removal
Inspection
Installation
Front Shock Absorber And Front Arms
Removal
Inspection
Installation
Rear Shock Absorber And Swingarm
Removal
Inspection
Installation

Chapter 8 Electrical
YFM400FW Circuit Diagram
Color Code
Electrical Components
Checking Of Connections
Ignition System
Circuit Diagram
Troubleshooting
Electrical Starting System
Circuit Diagram
Starting Circuit Operation
Troubleshooting
Starter Motor
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Lighting System Check
Signal System
Circuit Diagram
Troubleshooting
Signal System Check
Cooling System
Circuit Diagram
Troubleshooting

Chapter 9 Troubleshooting
Starting Failure/hard Starting
Fuel System
Electrical System
Compression System
Poor Idle Speed Performance
Poor Idle Speed Performance
Poor Medium And High Speed Performance
Poor Medium And High Speed Performance
Faulty Drive Train
Faulty Gear Shifting
Hard Shifting
Shift Pedal Does Not Move
Jump-out Gear
Clutch Slipping/dragging
Clutch Slipping
Clutch Dragging
Overheating
Overheating
Faulty Brake
Poor Braking Effect
Shock Absorber Malfunction
Malfunction
Instable Handling
Instable Handling
Lighting System
Headlight Dark
Bulb Burnt Out
YFM400FW Wiring Diagram