Yamaha WR400FP 2001 Manuals

Manuals and User Guides for Yamaha WR400FP 2001. We have 1 Yamaha WR400FP 2001 manual available for free PDF download: Owner's Service Manual

YAMAHA WR400FP 2001 Owner's Service Manual

YAMAHA WR400FP 2001 Owner's Service Manual (777 pages)

Brand: YAMAHA | Category: Motorcycle | Size: 44.51 MB

Table of Contents

Important Notice
6
Safety Information
6
FIM Machine Weights
10
Introduction
10
Description
12
- Finding the Required Page
  12
- How to Use this Manual
  12
Renseignements Generaux
13
- How to Read Descriptions
  14
- Manual Format
  14
- Illustrated Symbols
  16
- Index
  18
- Table of Contents
  20
Chapter 7

26
- Description
  26
- Engine
  26
  - General Information
    26
  - Allgemeine Angaben
    27
Chapter 1

28
- Engine Serial Number
  28
- Machine Identification
  28
  - Model Label
    28
  - Vehicle Identification Number
    28
- Identification de la Machine
  29
- Important Information
  30
- Preparation for Removal and Disassembly
  30
- Informations Importantes
  31
  - Wichtige Informationen
    31
  - All Replacement Parts
    32
  - Bearings and Oil Seals
    32
  - Gaskets, Oil Seals and O-Rings
    32
  - Lock Washers/Plates and Cotter Pins
    32
  - Circlips
    34
- Checking of Connection
  36
- Verification des Connexions
  37
- Special Tools
  38
- Outils Speciaux
  41
  - Herramientas Especiales
    47
  - "Engine Stop" Button
    50
  - Clutch Lever
    50
- Control Functions
  50
- Shift Pedal
  50
- Fonctions des Commandes
  51
- Funciones de Control
  51
  - Decompression Lever
    52
  - Front Brake Lever
    52
  - Rear Brake Pedal
    52
  - Throttle Grip
    52
  - Cold Starter Knob
    54
  - Fuel Cock
    54
  - Hot Starter Knob
    54
  - Flap
    56
  - Lights Switch
    56
  - Valve Joint
    56
  - Fuel
    58
- Essence
  59
- Starting and Break-In
  60
  - Starting Ba Cold Engine
    60
  - Anlassen und Einfahren
    61
- Arranque y Rodaje
  61
- Mise en Marche Et Rodage
  61
  - Restarting an Engine after a Fall
    64
  - Starting a Warm Engine
    64
  - The Engine Fails to Start
    64
  - Break-In Procedures
    66
- Torque-Check Points
  66
- Torque-Check Points
  68
- Points de Verification de Couple de Serrage
  69
- Anzugsmomente Kontrollieren
  70
- Cleaning and Storage
  72
- Limpieza y Almacenamiento
  73
- Nettoyage Et Rangement
  73
- General Specifications (WR426F)
  76
- Chassis
  77
Chapter 2

110
- Definition of Units
  110
- General Torque Specifications
  110
- Caracteristiques
  111
- Caracteristiques Generales (Wr426F)
  111
- Caracteristiques D'entretien (Wr426F)
  114
- Caracteristiques Generales (Wr400F)
  128
- Caracteristiques D'entretien (Wr400F)
  131
- Caracteristiques Generales de Couple
  145
- Definition des Unites
  145
- Moteur
  145
- Allgemeine Technische
  146
- Kraftstoff
  147
- Wartungsdaten (Wr426F)
  149
- Allgemeine Technische
  163
- Daten (Wr400F)
  163
- Wartungsdaten (Wr400F)
  166
- Allgemeine Anzugsmomente
  180
- Einheiten
  180
- Especificaciones de Apriete Generales
  215
- Lubrication Diagrams
  216
- Schaubilder
  217
- Schmiersystem
  217
- Cable Routing Diagram
  220
  - Cheminement des Cables
    221
  - Diagrama de Ruta de Cables
    221
- Kabelführung
  221
Chapter 3

232
- Maintenance Intervals
  232
- Regular Inspection and Adjustments
  232
- Motor
  238
- Regelmässige Inspektion und Einstellarbeiten
  238
- Wartungsintervalle und Schmierdienst
  238
- Anlassen und Einfahren
  239
- Fahrwerk
  239
  - Chassis
    244
  - Engine
    244
  - General Inspection and Maintenance
    244
  - Pre-Operation Inspection and Maintenance
    244
- A la Conducción
  247
  - Coolant Replacement
    248
  - Engine/Coolant Level Inspection
    248
- Motor
  249
  - And Side Covers
    250
  - Radiator Cap Inspection
    254
  - Radiator Cap Opening Pressure Inspection
    254
  - Cooling System Inspection
    256
  - Clutch Adjustment
    258
  - Clutch Lever Free Play Adjustment Steps
    258
  - Throttle Cable Adjustment
    258
  - Throttle Grip Free Play Adjustment Steps
    260
  - Throttle Lubrication
    260
  - Adjustment Steps
    262
  - Air Filter Cleaning
    262
  - Checking Steps
    262
  - Decompression Lever Adjustment
    262
  - Engine Oil Level Inspection
    266
  - Engine Oil Replacement
    270
  - Engine Oil Replacement
    272
  - Pilot Screw Adjustment
    274
  - Idle Speed Adjustment
    276
  - Valve Clearance Adjustment
    276
  - Valve Clearance Adjustment
    286
  - Spark Arrester Cleaning (for USA)
    290
  - Brake System Air Bleeding
    292
  - Chassis
    292
- Chasis
  293
  - Partie Cycle
    293
  - Brake Level Position
    294
  - Brake Level Position Adjustment Steps
    294
  - Front Brake Adjustment
    294
  - Brake Pad Thickness
    296
  - Front Brake Pad Inspection and Replacement
    296
  - Pedal Height Adjustment Steps
    296
  - Rear Brake Adjustment
    296
  - Rear Brake Pad Inspection and Replacement
    300
  - Brake Fluid Level Inspection
    304
  - Rear Brake Pad Insulator Inspection
    304
  - Drive Chain Inspection
    306
  - Sprockets Inspection
    306
  - Drive Chain Lubricant
    308
  - Drive Chain Slack Adjustment
    310
  - Front Fork Inspection
    312
  - Front Fork Oil Seal and Dust Seal Cleaning
    312
  - Front Fork Internal Pressure Relieving
    314
  - Front Fork Rebound Damping Force Adjustment
    314
  - Front Fork Compression Damping Force Adjustment
    316
  - Rear Shock Absorber Inspection
    318
  - Rear Shock Absorber Spring Preload Adjustment
    320
  - Rear Shock Absorber Rebound Damping Force Adjustment
    322
  - Rear Shock Absorber Low Compression Damping Force Adjustment
    324
  - Rear Shock Absorber High Compression Damping Force Adjustment
    326
  - Spokes Inspection and Tightening
    328
  - Tire Pressure Check
    328
  - Wheel Inspection
    328
  - Steering Head Inspection and Adjustment
    330
  - Steering Ring Nut Adjustment Steps
    330
  - Lubrication
    334
CHAPTER 6 Electrical

336
- Spark Plug Inspection
  336
- Moteur
  337
- Sistema Eléctrico
  337
  - Ignition Timing Check
    338
  - Replacing the Headlight Bulbs
    340
  - Adjusting the Headlight Beams
    342
Chapter 4

344
- Engine
  344
- Seat, Fuel Tank and Side Covers
  344
- Seat, Fuel Tank and Side Covers Removal
  344
- Exhaust Pipe and Silencer
  346
- Radiator
  350
  - Radiator Removal
    350
  - Handling Note
    354
  - Radiator Assembly and Installation
    354
  - Radiator Inspection
    354
- Carburetor
  358
  - Carburetor Removal
    358
  - Carburetor Disassembly
    360
  - Carburetor Inspection
    364
  - Carburetor Removal Points
    364
  - Jet Needle Inspection
    366
  - Needle Valve Inspection
    366
  - Throttle Valve Inspection
    366
  - Float Height Inspection
    368
  - Float Inspection
    368
  - Accelerator Pump
    370
  - Air Cut Valve
    370
  - Carburetor Assembly and Installation
    370
  - Starter Plunger
    370
  - Accelerator Pump Timing Adjustment
    380
  - Throttle Valve Height
    380
  - Camshaft
    386
  - Cylinder Head Cover
    386
  - Cylinder Head Cover Removal
    386
- Arbres a Cames
  387
  - Camshafts Removal
    388
  - Rboles de Levas
    389
  - Camshaft Removal Point
    390
  - Camshaft Inspection
    392
  - Camshaft Sprocket
    394
  - Camshaft Assembly and Installation
    396
  - Timing Chain Tensioner
    396
- Cylinder Head
  400
  - Cylinder Head Removal
    400
  - Cylinder Head Inspection
    404
  - Warpage Measurement and Resurfacement Steps
    404
  - Cylinder Head Assembly and Installation
    406
  - Valves and Valve Spring Removal
    408
- Valves and Valve Springs
  408
  - Soupapes Et Ressorts de Soupape
    409
  - Ventile und Ventilfedern
    409
  - Removal Points
    410
  - Valve Inspection
    412
  - Lapping Steps
    418
  - Valve Lifter Inspection
    420
  - Valve Spring Inspection
    420
  - Assembly and Installation
    422
  - Combination of Cylinder Head and Valve Lifter
    422
- Cylinder and Piston
  426
- Cylinder and Piston Removal
  426
- Cylindre Et Piston
  427
- Zylinder und Kolben
  427
  - Cylinder and Piston Inspection
    428
  - Piston Removal Points
    428
  - Piston Ring Removal Points
    428
  - Piston Ring Inspection
    432
  - Piston Pin Inspection
    434
  - Piston Assembly and Installation
    436
- Clutch (WR426F)
  440
  - Clutch Removal
    440
  - Clutch Boss Removal Points
    444
  - Clutch Housing and Boss Inspection
    444
  - Clutch Spring Inspection
    444
  - Primary Driven Gear Inspection
    444
  - Clutch Plate Inspection
    446
  - Friction Plate Inspection
    446
  - Push Lever Inspection
    446
  - Push Rod Inspection
    446
  - Clutch Assembly and Installation
    448
  - Push Lever Assembly and Installation
    448
- Clutch (WR400F)
  454
- Balancer
  482
  - Balancer Removal
    482
  - Balancer, Balancer Drive Gear and Balancer Driven Gear Assembly and Installation
    486
- Oil Pump
  488
- Oil Pump Removal and Disassembly
  488
- Bomba de Aceite
  489
- Pompe a Huile
  489
  - Oil Pump Assembly and Installation
    492
  - Oil Pump Inspection
    492
- Kick Axle and Shift Shaft
  496
- CDI Magneto
  510
- CDI Magneto Removal
  510
- Magneto CDI
  511
  - CDI Magneto Inspection
    512
  - Rotor Removal Points
    512
  - Woodruff Key Inspection
    512
  - CDI Magneto Assembly and Installation
    514
- Engine Removal
  518
- Depose du Moteur
  519
- Motor Demontieren
  519
  - Drive Sprocket Removal Points
    522
  - Engine Removal Points
    522
  - Brake Pedal Assembly and Installation
    524
  - Drive Sprocket Assembly and Installation
    524
  - Engine Installation
    524
  - Crankcase Separation
    528
  - Crankcse and Crankshaft
    528
- Carter Et Vilebrequin
  529
  - Crankcase Bearing
    532
  - Crankcase Bearing Removal
    532
  - Crankcase Removal Points
    534
  - Separation Steps
    534
  - Crankcase Inspection
    536
  - Crankshaft Bearing Removal Points
    536
  - Crankshaft Removal Points
    536
  - Timing Chain and Timing Chain Guide Inspection
    536
  - Crankshaft Inspection
    538
  - Oil Delivery Pipe Inspection
    538
  - Oil Strainer Inspection
    538
  - Crankshaft Assembly and Installation
    540
  - Crankshaft Bearing Assembly and Installation
    540
- Transmission, Shift Cam and Shift Fork
  546
Chapter 5 Chassis

556
- Front Wheel and Rear Wheel
  556
- Front Wheel Removal
  556
- Partie Cycle
  557
  - Rear Wheel Removal
    558
  - Roue Avant Et Roue Arriere
    559
  - Rear Wheel Removal Points
    560
  - Wheel Bearing Removal Points
    560
  - Brake Disc Removal Points
    562
  - Wheel Axle Removal Points
    562
  - Front Wheel Assembly and Installation
    564
  - Rear Wheel Assembly and Installation
    570
- Front Brake and Rear Brake
  576
  - Front Brake Removal
    576
  - Frein Avant Et Frein Arriere
    577
  - Rear Brake Removal
    578
  - Caliper Disassembly
    580
  - Master Cylinder Disassembly
    582
  - Brake Fluid Removal Points
    584
  - Calliper Piston Removal Points
    584
  - Master Cylinder Inspection
    586
  - Piston Seal Kit Removal Points
    586
  - Brake Hose Inspection
    588
  - Caliper Inspection
    588
  - Caliper Piston Assembly and Installation
    588
  - Front Caliper Assembly and Installation
    590
  - Rear Caliper Assembly and Installation
    592
  - Master Cylinder Kit Assembly and Installation
    596
  - Front Master Cylinder Assembly and Installation
    598
  - Rear Master Cylinder Assembly and Installation
    600
  - Front Brake Hose Assembly and Installation
    602
  - Rear Brake Hose Assembly and Installation
    604
  - Brake Fluid
    606
- Front Fork
  610
- Frontfork Removal
  610
- Fourche Avant
  611
  - Horquilla Delantera
    611
  - Front Fork Disassembly
    612
  - Cap Bolt Removal Points
    614
  - Damper Rod Inspection
    616
  - Damper Rod Removal Points
    616
  - Inner Tube Removal Points
    616
  - Base Valve Inspection
    618
  - Fork Spring
    618
  - Inner Tube Inspection
    618
  - Outer Tube Inspection
    618
  - Cap Bolt Inspection
    620
  - Front Fork Assembly
    620
  - Front Fork Installation
    632
- Handlebar
  636
  - Handlebar Removal
    636
  - Grip Removal Points
    638
  - Handlebar Assembly and Installation
    638
  - Handlebar Inspection
    638
  - Master Cylinder Removal Points
    638
- Steering
  648
  - Steering Removal
    648
  - Ball Race Removal Points
    652
  - Bearing (Lower) Removal Points
    652
  - Ring Nut Removal Points
    652
  - Steering Shaft Inspection
    652
  - Bearing and Ball Race
    654
  - Under Bracket Assembly and Installation
    654
- Swingarm
  660
  - Swingarm Removal
    660
  - Frein Avant Et Frein Arriere
    661
  - Swingarm Disassembly
    662
- Bras Oscillant
  663
  - Bearing Removal Points
    664
  - Connectig Rod Inspection
    664
  - Relay Arm Inspection
    664
  - Swingarm Inspection
    664
  - Bearing and Oil Seal Assembly and Installation
    666
  - Swingarm Assembly and Installation
    668
- Rear Shock Absorber
  674
- Rear Shock Absorber Removal
  674
- Et Caches Lateraux
  675
- Radiateur
  675
  - Tuyau D'echappement Et Silencieux
    675
  - Amortiguador Trasero
    677
- Amortisseur Arriere
  677
- Motor
  691
  - Partie Electrique
    691
  - 3-D Image Map of Ignition Timing
    692
  - Function of Component
    692
- Ignition System
  692
- Map-Controlled CDI Unit
  692
- Combustible
  699
  - Herramientas Especiales
    699
  - "Engine Stop" Button Inspection
    700
  - Couplers and Leads Conection Inspection
    700
  - Spark Gap Test
    700
  - Sistema de Encendido
    701
  - Ignition Coil Inspection
    702
  - CDI Unit Inspection
    704
  - Neutral Switch Inspection
    704
  - TPS (Throttle Position Sensor) System Inspection Steps
    706
  - Couplers and Leads Connection Inspection
    710
  - TPS Coil Inspection
    710
  - TPS Replacement and Adjustment
    712
- Carburateur
  713
  - TPS Input Voltage Inspection
    716
  - Lighting System Inspection Steps
    718
- Magneto CDI
  721
  - Lights Switch Inspection
    722
  - Regulator Inspection
    722
  - Sistema de Alumbrado
    723
  - Carburetor Setting
    724
  - Tuning
    724
- Carburador
  725
- Vergaser
  725
- Guidon
  755
  - Front Fork Setting Parts
    756
  - Choosing Set Length
    758
  - Rear Suspension Setting
    758
  - Rear Shock Absorber Setting Parts
    764
  - Suspension Setting
    766
- Federbein
  770
- Teleskopgabel
  770

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