2002-2006 yamaha YFM400 Kodiak Service Repair Manual

CONTENTS SPECIFICATIONS ............................................................................................1 GENERAL SPECIFICATIONS ..................................................................1 MAINTENANCE SPECIFICATIONS .........................................................3 ENGINE ................................................................................................3 CHASSIS ..............................................................................................4 ELECTRICAL ........................................................................................5 CABLE ROUTING .....................................................................................6 PERIODIC CHECKS AND ADJUSTMENTS ..................................................20 INTRODUCTION .....................................................................................20 PERIODIC MAINTENANCE/LUBRICATION ...........................................20 CHASSIS .................................................................................................22 ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................22 ELECTRICAL .................................................................................................23 CHECKING THE SWITCH ......................................................................23 CHECKING THE SWITCH ..................................................................23 CHECKING A SWITCH SHOWN IN THE MANUAL ...........................23 IGNITION SYSTEM .................................................................................24 CIRCUIT DIAGRAM ............................................................................24 TROUBLESHOOTING ........................................................................25 ELECTRIC STARTING SYSTEM ............................................................30 CIRCUIT DIAGRAM ............................................................................30 TROUBLESHOOTING ........................................................................31 LIGHTING SYSTEM ................................................................................34 CIRCUIT DIAGRAM ............................................................................34 SIGNAL SYSTEM ...................................................................................35 CIRCUIT DIAGRAM ............................................................................35 CHECKING THE SIGNAL SYSTEM ...................................................37 YFM40FPP/YFM400FW(P) 2002 WIRING DIAGRAM

– 1 – SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM40FPP/YFM400FW(P) 2002 Model code: 4SHR (CDN) 4SHS (Europe) 4SHT (Oceania) Dimensions: Overall length 1,956 mm (77.0 in) Overall width 1,155 mm (45.5 in) Overall height 1,144 mm (45.0 in) Seat height 845 mm (33.3 in) Wheelbase 1,210 mm (47.6 in) Minimum ground clearance 215 mm (8.46 in) Minimum turning radius 3,500 mm (137.8 in) Fuel: Type Regular unleaded fuel (CDN) Regular unleaded fuel (Europe) Unleaded fuel (Oceania) Fuel tank capacity 13.5 L (2.97 Imp gal, 3.57 US gal) Fuel reserve amount 1.3 L (0.29 Imp gal, 0.34 US gal) Chassis: Frame type Steel tube frame Caster angle 2.5° Camber angle 0° Kingpin angle 12° Trail 15 mm (0.59 in) Tread (STD) Rear 820 mm (32.28 in) Tread (STD) Front 850 mm (33.46 in) Toe-in 5 ~ 15 mm (0.20 ~ 0.59 in) Brake: Front brake Type Dual disc brake Operation Right hand operation Rear brake Type Drum brake Operation Left hand and right foot operation Electrical: Ignition system DC. C.D.I Generator system A.C. magneto Battery type YTX20L-BS Battery capacity 12 V 18 AH Headlight type: Krypton bulb

– 2 – SPEC GENERAL SPECIFICATIONS Bulb wattage × quantity: Headlight 12 V 30 W/30 W × 2 Tail/brake light 12 V 5.0 W/21 W × 1 Meter light 14 V 3.0 W/1 Indicator light: NEUTRAL 12 V 1.7 W × 1 REVERSE 12 V 1.7 W × 1 OIL TEMPERATURE 12 V 1.7 W × 1 Model YFM40FPP/YFM400FW(P) 2002

– 3 – SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFM40FPP/YFM400FW(P) 2002 Valve spring: Inner spring: Free length IN 39.9 mm (1.57 in) EX 39.9 mm (1.57 in) <Limit> IN <37.9 mm (1.49 in)> EX <37.9 mm (1.49 in)> Set length (valve closed) IN 33.6 mm (1.3 in) EX 33.6 mm (1.3 in) Compressed pressure IN 105 ~ 121 N (10.70 ~ 12.30 kg, 23.58 ~ 27.11 lb) (installed) EX 105 ~ 121 N (10.70 ~ 12.30 kg, 23.58 ~ 27.11 lb) Tilt limit IN 2.5°/1.6 mm (2.5°/0.06 in) EX 2.5°/1.6 mm (2.5°/0.06 in) Direction of winding IN Counterclockwise (top view) EX Counterclockwise Outer spring: Free length IN 43.27 mm (1.70 in) EX 43.27 mm (1.70 in) <Limit> IN <41.27 mm (1.62 in)> EX <41.27 mm (1.62 in)> Set length (valve closed) IN 36.6 mm (1.4 in) EX 36.6 mm (1.4 in) Compressed pressure IN 235 ~ 251 N (24.00 ~ 25.60 kg, 52.92 ~ 56.45 lb) (installed) EX 235 ~ 251 N (24.00 ~ 25.60 kg, 52.92 ~ 56.45 lb) Tilt limit IN 2.5°/1.6 mm (2.5°/0.06 in) EX 2.5°/1.6 mm (2.5°/0.06 in)

– 4 – SPEC MAINTENANCE SPECIFICATIONS CHASSIS Direction of winding IN Clockwise (top view) EX Clockwise Model YFM40FPP/YFM400FW(P) 2002 Front suspension: Shock absorber travel 67.5 mm (2.66 in) Fork spring free length 229.5 mm (9.04 in) Spring fitting length 179.5 mm (7.07 in) Spring rate (K1) 19.6 N/mm (1.96 kg/mm, 111 lb/in) Stroke (K1) 0 ~ 67.5 mm (0.00 ~ 2.66 in) Optional spring No Front disk brake: Type Single Disc outside diameter × thickness 180 × 3.5 mm (7.09 × 0.14 in) Pad thickness 4.5 mm (0.18 in) <Limit> <1.0 mm (0.04 in)> Master cylinder inside diameter 14.00 mm (0.55 in) Caliper cylinder inside diameter 32 mm (1.26 in) Brake fluid type DOT 4 Model YFM40FPP/YFM400FW(P) 2002

– 5 – SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Tightening torque Model YFM40FPP/YFM400FW(P) 2002 C.D.I.: Magneto model/manufacturer F4T46671/MITSUBISHI Pickup coil resistance/color 459 ~ 561 Ω at 20 °C (68 °F)/(White/Red- White/Green) Rotor rotation direction sensing coil resistance 0.103 ~ 0.127 Ω at 20 °C (68 °F)/(Red- White/Blue) C.D.I. unit model/manufacturer F8T38673/MITSUBISHI Charging system: Type A.C. magneto generator Model/manufacturer F4T46671/MITSUBISHI Nominal output 14 V 19 A at 5,000 r/min Charging coil resistance/color 0.702 ~ 0.858 Ω at 20 °C (68 °F)/(White-White) Rectifier/regulator: Regulator type Semi conductor-short circuit Model/manufacturer SH640E-11/SHINDENGEN No load regulated voltage 14.1 ~ 14.9 V Rectifier capacity 14 A Withstand voltage 200 V Battery: Specific gravity 1,320 Horn: Type Plane type Quantity 1 Model/manufacturer MF-12/NIKKO Maximum amperage 1.5 A Performance 100 ~ 108 db/2 m Coil resistance 4.3 ~ 4.8 Ω Parts to be tightened Parts name Thread size Q´ty Tightening torque Remarks Nm m · kg ft · lb Frame and bearing retainer (steering shaft holder bearing) Nut M42 × 1 1 65 6.5 47 Steering shaft and frame Nut M10 × 1.25 1 23 2.3 17 Steering shaft holder and handlebar holder (upper) Bolt M8 × 1.25 4 20 2.0 14 Nut M10 × 1.25 4 15 1.5 11

– 6 – SPEC CABLE ROUTING 1 Rear brake switch 2 Rear brake cable 3 Starter cable 4 Auxiliary DC jack lead 5 Front brake hose 6 Front brake light switch 7 Throttle cable 8 Horn (for Europe and Oceania) 8 1 2 3 4 5 6 7 È É Ê Ë CABLE ROUTING

– 7 – SPEC È Fasten the front brake light switch lead to the handlebar with the plastic band. É Route the fuel tank breather hose through the hole in the handlebar cover. Ê Fasten the handlebar switch lead and rear brake switch lead to the handlebar with the plastic band. Ë Fasten the handlebar switch lead, rear brake switch lead and horn lead to the handlebar with the plastic band. (for Europe and Oceania) 8 1 2 3 4 5 6 7 È É Ê Ë CABLE ROUTING

– 8 – SPEC 1 Front brake light switch lead 2 Front brake hose 3 Throttle cable 4 Speedometer cable 5 Speedometer lead 6 Main switch lead 7 Oil temperature indicator light lead 8 Handlebar switch lead 9 Rear brake switch lead 0 Starter cable A Rear brake cable B Reverse control cable 2 C Differential gear case breather hose 1 2 3 4 5 67 8 9 0 A C 2 B È CABLE ROUTING

2002-2006 yamaha YFM400 Kodiak Service Repair Manual

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