radiator YAMAHA WR 400F 2000 User Guide

3 - 5
INSP
ADJ

EC350000
ENGINE
EC351011
COOLANT LEVEL INSPECTION
WARNING

Do not remove the radiator cap
1
, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:

Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Inspect:
l
Coolant level
Coolant level should be between the
maximum
a
and minimum
b
marks.
Coolant level is below the “LOW” level
line
®
Add soft water (tap water) up to
the proper level.
3. Start the engine and let it warm up for
several minutes.
4. Turn off the engine and check the coolant
level again.
NOTE:

Before checking the coolant level, wait a few
minutes until the coolant settles.
LOWFULLCOOLANT
a
b

EC353011
COOLANT REPLACEMENT
WARNING

Do not remove the radiator cap when the
engine is hot.
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT

3 - 6
INSP
ADJ

COOLANT REPLACEMENT
CAUTION:

Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.
1. Place a container under the engine.
2. Remove:
l
Seat
Refer to ”SEAT FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
3. Disconnect:
l
Coolant reservoir hose
1

Drain the coolant completely.
4. Connect:
l
Coolant reservoir hose
LOWFULLCOOLANT1

5. Remove:
l
Engine guard
1

l
Coolant drain bolt
2

6. Remove:
l
Radiator cap
Drain the coolant completely.
7. Clean:
l
Cooling system
Thoroughly flush the cooling system
with clean tap water.
8. Install:
l
Copper washer
l
Coolant drain bolt
l
Engine guard
9. Fill:
l
Radiator
l
Engine
To specified level.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant
1 and water
(soft water) 2 mixing ratio:
50%/50%
Coolant capacity:
1.2 L (1.06 Imp qt, 1.27 US qt)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:
lDo not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
lDo not use water containing impurities or oil.
10. Install:
lRadiator cap
11. Fill:
lCoolant reservoir tank
Midway b between maximum and min-
imum marks on the tank.
12. Install:
lCoolant reservoir cap
13. Start the engine and let it warm up for
several minutes.
14. Turn off the engine and inspect the cool-
ant level.
Refer to “COOLANT LEVEL INSPEC-
TION” section.
NOTE:
Before checking the coolant level wait a few
minutes until the coolant settles.Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
lWhen coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
lWhen coolant splashes to your
clothes.
Quickly wash it away with water and
then with soap.
lWhen coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
LOWFULLCOOLANTb
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
lSeal (radiator cap) 1
lValve and valve seat 2
Crack/damage ® Replace.
Fur deposits 3 ® Clean or replace.

3 - 8
INSP
ADJRADIATOR CAP OPENING PRESSURE INSPECTION/
COOLING SYSTEM INSPECTION
EC356001
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
lRadiator cap tester 1 and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
3. Inspect:
lPressure
Impossible to maintain the specified
pressure for 10 seconds ® Replace.
Radiator cap tester:
YU-24460-1/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
110 kPa (1.1 kg/cm2, 15.6 psi)
EC357002
COOLING SYSTEM INSPECTION
1. Inspect:
lCoolant level
2. Attach:
lRadiator cap tester 1 and adapter 2
3. Apply the specified pressure.
Radiator cap tester:
YU-24460-1/90890-01325
Adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)

3 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
lDo not apply pressure more than specified
pressure.
lRadiator should be filled fully.
4. Inspect:
lPressure
Impossible to maintain the specified
pressure for 10 seconds ® Repair.
lRadiator
lRadiator hose joint
Coolant leakage ® Repair or replace.
lRadiator hose
Swelling ® Replace.
EC359001
CLUTCH ADJUSTMENT
1. Check:
lClutch lever free play a
Out of specification ® Adjust.
Clutch lever free play a:
2 ~ 4 mm (0.08 ~ 0.16 in)
2. Adjust:
lClutch lever free play
NOTE:
lMake minute adjustment on the lever side
using the adjuster 3.
lAfter adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 2 until free play a is
within the specified limits.
lTighten the locknut.

3 - 18
INSP
ADJIDLE SPEED ADJUSTMENT/
VALVE CLEARANCE ADJUSTMENT
EC35M021
IDLE SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it
up.
2. Adjust:
lIdle speed
Adjustment steps:
lAdjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.
lTurn the throttle stop screw 1 until the
engine runs at the lowest possible speed.
To increase idle speed ®
Turn the throttle stop screw 1 in a.
To decrease idle speed ®
Turn the throttle stop screw 1 out b.
Engine idling speed:
1,700 ~ 1,900 r/min
VALVE CLEARANCE ADJUSTMENT
NOTE:
lThe valve clearance should be adjusted
when the engine is cool to the touch.
lThe piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.
1. Remove:
lSeat
lSide covers
lAir scoops
lFuel tank
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
2. Drain:
lCoolant
Refer to “COOLANT REPLACEMENT”
section.
3. Remove:
lRADIATOR
Refer to “RADIATOR” section in the
CHAPTER 4.
lEngine stay (upper)
lCylinder head breather hose
lCylinder head cover
lSpark plug cap
Refer to “CYLINDER HEAD COVER”
section in the CHAPTER 4.

ENG

4 - 3
RADIATOR
EC450001
RADIATOR

For USA, CDN
õ
Except for USA, CDN
Extent of removal:
1
Radiator removal
2
Coolant reservoir removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat, fuel tank and side Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
1 Engine guard 1
2 Panel 2 Refer to “REMOVAL POINTS”.
(Except for USA, CDN)
3 Clamp 8
4 Radiator (right) 1
5 Hose 2 1
6 Hose 3 1
7 Hose 4 1
8 Pipe 2/O-ring 1/1
1

ENG

4 - 4
RADIATOR

For USA,CDN
õ
Except for USA, CDN
Extent of removal Order Part name Q’ty Remarks
9 Radiator breather hose 1
10 Radiator (left) 1
11 Hose 1 1
12 Pipe 1/O-ring 1/1
13 Coolant reservoir hose 1
14 Coolant reservoir breather hose 1
15 Coolant reservoir tank 1
2
1

4 - 5
ENG

RADIATOR
EC456000
HANDLING NOTE
WARNING

Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC453000
REMOVAL POINTS
EC453200
Panel (Except for USA, CDN)
1. Remove:
l
Panel
1

NOTE:

l
Unhook the panel first on the outer side
a
and then on the inner side.
l
Take care not to bend the panel more than
necessary.
EC454000
INSPECTION
EC444100
Radiator
1. Inspect:
l
Radiator core
1

Obstruction
®
Blow out with com-
pressed air through rear of the radiator.
Bent fin
®
Repair/replace.

4 - 6
ENG

RADIATOR
EC455000
ASSEMBLY AND INSTALLATION
EC445350
Radiator
1. Install:
l
Pipe 1
1

l
Hose 1
2

l
Pipe 2
3

l
Hose 3
4

l
Hose 4
5

2. Install:
l
Hose 2
1

l
Radiator (left)
2

3. Install:
l
Radiator breather hose
1

l
Radiator (right) 2
Refer to “CABLE ROUTING DIA-
GRAM” section in the CHAPTER 2.
4. Install:
[For USA, CDN]
lPanel 1
NOTE:
lTake care not to bend the panel more than
necessary.
lHook the panel first on the inner side a and
then on the outer side.

[Except for USA, CDN]
lPanel 1
lBolt (radiator panel upper) 2
NOTE:
Fit the hook a on the inner side first into the
radiator.

For USA, CDN
õ Except for USA, CDN
õ