width YAMAHA WR 400F 2000 Notices Demploi (in French)

2 - 1
SPEC

GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: WR400F (EUROPE)
WR400FM (USA)
WR400F(M) (CDN, AUS, NZ, ZA)
Model code number: 5GS5 (USA)
5GS6 (EUROPE)
5GS8 (CDN, AUS, NZ, ZA)
Dimensions:
Overall length 2,171 mm (85.5 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 998 mm (39.3 in)
Wheelbase 1,490 mm (58.7 in)
Minimum ground clearance 373 mm (14.7 in)
Basic weight:
With oil and full fuel tank 122.0 kg (270 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 399 cm
3

(14.1 Imp oz, 13.5 US oz)
Bore

´

stroke 92.0
´
60.1 mm (3.62
´
2.37 in)
Compression ratio 12.5 : 1
Starting system Kick starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil
[For USA and CDN]
At 5 ˚C (40 ˚F) or higher

Yamalube 4 (20W-
40) or SAE 20W-40 type SH motor oil (Non-
Friction modified)
At 15 ˚C (60 ˚F) or lower
õ
Yamalube 4 (10W-
30) or SAE 10W-30 type SH motor oil (Non-
Friction modified) and/or Yamalube 4-R (15W-
50) (Non-Friction modified)
[Except for USA and CDN]
API “SH” or higher grade
(Designed primarily for motorcycles)
-20
-4-10
140
3010
5020
6830
8640 50
104
122¡CTemp.
¡F
10W/30
10W/40
20W/40
20W/50

2

2 - 5
SPEC

MAINTENANCE SPECIFICATIONS
Cam chain:
Cam chain type/No. of links 92RH2010-120MPX/120 ----
Cam chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)----
EX 0.25 ~ 0.30 mm
(0.0098 ~ 0.0118 in)----
Valve dimensions:
“A” head diameter IN 26.9 ~ 27.1 mm
(1.0591 ~ 1.0669 in)----
EX 27.9 ~ 28.1 mm
(1.0984 ~ 1.1063 in)----
“B” face width IN 2.26 mm (0.089 in) ----
EX 2.26 mm (0.089 in) ----
“C” seat width IN0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.5 mm
(0.0591 in)
EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.5 mm
(0.0591 in)
“D” margin thickness IN 1 mm (0.0394 in) 0.85 mm
(0.033 in)
EX 1 mm (0.0394 in) 0.85 mm
(0.033 in)
Stem outside diameter IN4.475 ~ 4.490 mm
(0.1762 ~ 0.1768 in)----
EX 4.960 ~ 4.975 mm
(0.1953 ~ 0.1959 in)----
Guide inside diameter IN 4.500 ~ 4.512 mm
(0.1772 ~ 0.1776 in)----
EX 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)----
Stem-to-guide clearance IN0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)0.08 mm
(0.003 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)0.10 mm
(0.004 in) Item Standard Limit
Head Diameter
B
Face WidthC
Seat Width
D
Margin ThicknessA

2 - 6
SPEC

MAINTENANCE SPECIFICATIONS
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)----
EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)----
Valve spring:
Free length IN 40.37 mm (1.59 in) 39.4 mm
(1.55 in)
EX 42.66 mm (1.68 in) 41.7 mm
(1.64 in)
Set length (valve closed) IN 32.86 mm (1.29 in) ----
EX 35.38 mm (1.39 in) ----
Compressed pressure
(installed) IN 117 ~ 134 N
(11.9 ~ 13.7 kg, 26.23 ~ 30.20 lb)----
EX 126 ~ 138 N
(12.9 ~ 14.1 kg, 28.44 ~ 31.08 lb)----
Tilt limit IN ----2.5˚/1.8 mm
(2.5˚/0.067 in)
EX ----2.5˚/1.9 mm
(2.5˚/0.075 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D” 91.945 ~ 91.960 mm
(3.6199 ~ 3.6205 in)----
Measuring point “H” 9 mm (0.354 in) ----
Piston off-set 1 mm (0.0394 in) ----Item Standard Limit
*
H
D

2 - 7
SPEC

MAINTENANCE SPECIFICATIONS
Piston pin bore inside diameter18.004 ~ 18.015 mm
(0.7088 ~ 0.7093 in)----
Piston pin outside diameter17.991 ~ 18.000 mm
(0.7083 ~ 0.7087 in)----
Piston rings:
Top ring
Type Barrel ----
Dimensions (B

´

T) 1.2
´
3.5 mm (0.05
´
0.14 in) ----
End gap (installed) 0.20 ~ 0.35 mm
(0.008 ~ 0.014 in)0.7 mm
(0.028 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.13 mm
(0.005 in)
2nd ring
Type Taper ----
Dimensions (B

´

T) 1.00
´
3.35 mm (0.04
´
0.13 in) ----
End gap (installed) 0.40 ~ 0.55 mm
(0.016 ~ 0.022 in)0.8 mm
(0.031 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.13 mm
(0.005 in)
Oil ring
Dimensions (B

´

T) 2.0
´
2.9 mm (0.08
´
0.11 in) ----
End gap (installed) 0.2 ~ 0.5 mm (0.01 ~ 0.02 in) ----
Crankshaft:
Crank width “A” 61.95 ~ 62.00 mm
(2.439 ~ 2.441 in)----
Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D” 0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F” 0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm
(0.08 in)
Balancer:
Balancer drive method Gear ----
Decompression device:
Type Manual ----
Cable free play 5 ~ 9 mm (0.20 ~ 0.35 in)
Air filter oil grade: Engine oil ----Item Standard Limit
T
B
B
T
B
T

2 - 9
SPEC

MAINTENANCE SPECIFICATIONS
Lubrication system:
Oil filter type Wire mesh type ----
Oil pump type Trochoid type ----
Tip clearance “A” 0.07 ~ 0.12 mm
(0.0028 ~ 0.0047 in)0.15 mm
(0.006 in)
“B” 0.09 ~ 0.15 mm
(0.0035 ~ 0.0059 in)0.22 mm
(0.009 in)
Side clearance 0.03 ~ 0.08 mm
(0.0012 ~ 0.0031 in)0.15 mm
(0.006 in)
Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm
2

,
5.69 ~ 11.38 psi)----
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) ----
Height 260 mm (10.2 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure110 kPa (1.1 kg/cm
2

, 15.6 psi)----
Radiator capacity (total) 0.76 L (0.67 lmp qt, 0.80 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

4 - 24
ENGCAMSHAFTS

Measurement steps:
lInstall the camshaft onto the cylinder
head.
lPosition a strip of Plastigauge® 1 onto the
camshaft.
lInstall the circlip, dowel pins and camshaft
caps.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m • kg, 7.2 ft • lb)
.
lRemove the camshaft caps and measure
the width of the Plastigauge
® 1.
NOTE:
lTighten the bolts (camshaft cap) in a
crisscross pattern from innermost to outer
caps.
lDo not turn the camshaft when measuring
clearance with the Plastigauge®.
5. Measure:
lBearing diameter (camshaft) a
Out of specification ® Replace the
camshaft.
Within specification ® Replace camshaft
case and camshaft caps as a set.
Camshaft sprocket
1. Inspect:
lCamshaft sprocket
Wear/damage ® Replace the camshaft
Assembly and timing chain as a set.
Bearing diameter (camshaft):
21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)

4 - 31
ENG

VALVES AND VALVE SPRINGS
REMOVAL POINTS
1. Remove:
l
Valve lifters
1

l
Pads
2

NOTE:

Identify each lifter
1
and pad
2
position very
carefully so that they can be reinstalled in their
original place.
2. Check:
l
Valve sealing
Leakage at the valve seat
®
Inspect
the valve face, valve seat and valve
seat width.
Checking steps:
l
Pour a clean solvent
1
into the intake and
exhaust ports.
l
Check that the valve seals properly.
There should be no leakage at the valve
seat
2
.
3. Remove:
l
Valve cotters
NOTE:

Attach a valve spring compressor
1
and
attachment
2
between the valve spring
retainer and the cylinder head to remove the
valve cotters.
Valve spring compressor:
YM-04019/90890-04019
Attachment:
YM-04108/90890-04108

4 - 33
ENG

VALVES AND VALVE SPRINGS
3. Inspect:
l
Valve face
Pitting/wear
®
Grind the face.
l
Valve stem end
Mushroom shape or diameter larger
than the body of the stem
®
Replace.
4. Measure:
l
Margin thickness
a

Out of specification
®
Replace.
5. Measure:
l
Runout (valve stem)
Out of specification
®
Replace.
NOTE:

l
When installing a new valve always replace
the guide.
l
If the valve is removed or replaced always
replace the oil seal.
6. Eliminate:
l
Carbon deposits
From the valve face and valve seat.
7. Inspect:
l
Valve seats
Pitting/wear
®
Reface the valve seat.
8. Measure:
l
Valve seat width
a

Out of specification
®
Reface the valve
seat.
Margin thickness:
Intake:
1.0 mm (0.039 in)
: 0.85 mm (0.033 in)
Exhaust:
1.0 mm (0.039 in)
: 0.85 mm (0.033 in)
Runout limit:
0.01 mm (0.0004 in)
Valve seat width:
Intake:
0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)
: 1.5 mm (0.06 in)
Exhaust:
0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)
: 1.5 mm (0.06 in)
NOTE:
After replacing the valve guide reface the
valve seat.

4 - 34
ENG

VALVES AND VALVE SPRINGS
Measurement steps:
l
Apply Mechanic’s blueing dye (Dykem)
b
to the valve face.
l
Install the valve into the cylinder head.
l
Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
l
Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
l
If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat
must be refaced.
9. Lap:
l
Valve face
l
Valve seat
NOTE:

After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps:
l
Apply a coarse lapping compound to the
valve face.
l
Apply molybdenum disulfide oil to the
valve stem.
l
Install the valve into the cylinder head.
l
Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
l
Apply a fine lapping compound to the
valve face and repeat the above steps.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.

4 - 35
ENG

VALVES AND VALVE SPRINGS
Valve spring
1. Measure:
lValve spring free length a
Out of specification ® Replace.
2. Measure:
lCompressed spring force a
Out of specification ® Replace.
bInstalled length
lApply Mechanic’s blueing dye (Dykem) to
the valve face.
lInstall the valve into the cylinder head.
lPress the valve through the valve guide
and onto the valve seat to make a clear
pattern.
lMeasure the valve seat width again. If the
valve seat width is out of specification,
reface and re-lap the valve seat.
Free length (valve spring):
Intake:
40.37 mm (1.59 in)
: 39.4 mm (1.55 in)
Exhaust:
42.66 mm (1.68 in)
: 41.7 mm (1.64 in)
Compressed spring force:
Intake:
117 ~ 134 kg (11.9 ~ 13.7 kg,
26.23 ~ 30.20 lb) at 32.86 mm
(1.29 in)
Exhaust:
126 ~ 138 N (12.9 ~ 14.1 kg,
28.44 ~ 31.08 lb) at 35.38 mm
(1.39 in)
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.
3. Measure:
lSpring tilt a
Out of specification ® Replace.
Spring tilt limit:
Intake:
2.5˚/1.8 mm (0.071 in)
Exhaust:
2.5˚/1.9 mm (0.075 in)