clutch YAMAHA WR 400F 2000 Owner's Guide

4 - 87
ENGCRANKCASE AND CRANKSHAFT
5. Install:
lDowel pin 1
lO-ring 2
lCrankcase (right)
To crankcase (left).
NOTE:
lFit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft ham-
mer.
lWhen installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
6. Tighten:
lHose guide 1
lClutch cable holder 2
lBolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
7. Install:
lOil delivery pipe
lO-ring
lBolt (oil delivery pipe)
8. Install:
lTiming chain
lTiming chain guide (rear)
lPlate washer
lBolt (timing chain guide)
9. Remove:
lSealant
Forced out on the cylinder mating sur-
face.
10. Apply:
lEngine oil
To the crank pin, bearing and oil deliv-
ery hole.
11. Check:
lCrankshaft and transmission operation.
Unsmooth operation ® Repair.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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CHAS
EC5B0000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate
1 Decompression cable 1 Disconnect at the lever side.
2 Decompression lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1
5 “ENGINE STOP” button 1
6 Lights switch 1
7 Master cylinder 1 Refer to “REMOVAL POINTS”.
8 Throttle cable cap 1
9 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
10 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
11 Grip (right) 1 Refer to “REMOVAL POINTS”.
12 Tube guide 1
13 Collar 1
14 Grip (left) 1 Refer to “REMOVAL POINTS”.
15 Handlebar holder (upper) 2
16 Handlebar 1
1
HANDLEBAR

5 - 43
CHASHANDLEBAR
5. Install:
lThrottle cable cap 1
lScrew (throttle cable cap) 3
lCover (throttle cable cap) 4
WARNING
After tightening the screws, check that the
throttle grip 4 moves smoothly. If it does
not, retighten the bolts for adjustment.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
6. Install:
lMaster cylinder 1
lMaster cylinder bracket 2
lBolt (master cylinder bracket) 3
NOTE:
lInstall the bracket so that the arrow mark a
faces upward.
lFirst tighten the bolt on the upper side of the
master cylinder bracket, and then tighten the
bolt on the lower side.
7. Install:
lLights switch 1
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
8. Install:
l“ENGINE STOP” button 1
lClutch lever holder 2
lBolt (clutch lever holder) 3
lDecompressor lever holder 4
lScrew (decompressor lever holder) 5
lClamp 6
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

5 - 44
CHASHANDLEBAR
NOTE:
lThe “ENGINE STOP” button, clutch lever
holder and clamp should be installed accord-
ing to the dimensions shown.
lPass the “ENGINE STOP” button lead in the
middle of the clutch holder.
9. Install:
lClutch cable 1
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
10. Adjust:
lClutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
11. Insert the end of the fuel breather hose
1 into the hole of the steering shaft.