engine YAMAHA WR 400F 2001 Manuale duso (in Italian)

5 - 1
CHAS

EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Break disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Trip meter cable 1
2 Hose cover 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Bolt (axle holder) 4 Only loosening.
5 Nut (front wheel axle) 1
6 Front wheel axle 1
7 Front wheel 1
8 Trip meter gear unit 1
9 Collar 1
10 Oil seal 1
11 Bearing 2 Refer to “REMOVAL POINTS”.
12 Brake disc 1
2
31
3

FRONT WHEEL AND REAR WHEEL




5

5 - 2
CHAS

EC598100
REAR WHEEL
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
REAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3

FRONT WHEEL AND REAR WHEEL

5 - 11
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:1 Brake hose removal2 Caliper removal
3 Master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
Drain the brake fluid.
WARNING
Support the machine securely so there is nodanger of it falling over.
Refer to “REMOVAL POINTS”.
1 Hose cover 1
2 Brake hose holder 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Caliper 1
9 Brake lever 1
10 Master cylinder bracket 1
11 Master cylinder 1
2
3
1
3
2

5 - 12
CHAS
EC5A8100
REAR BRAKE
Extent of removal:1 Caliper removal2 Brake hose removal
3 Master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Pad pin plug 1 Remove when loosening the pad pin.
2 Pad pin 1 Loosen when disassembling the caliper.
3 Caliper 1
4 Brake hose holder 2
5 Union bolt 2
6 Brake hose 1
7 Brake pedal 1
8 Reservoir tank 1
9 Reservoir hose 1
10Master cylinder
1
3
1
321
FRONT BRAKE AND REAR BRAKE

5 - 28
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (handle crown) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (under bracket) 2 Only loosening.
6 Front fork 1
1

5 - 41
CHAS
EC5B0000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Headlight
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 - 41
CHAS

LENKER
Demontage-Arbeiten:
1
Lenker demontieren
Demontage-ArbeitenReihen-
folgeBauteil Anz. Bemerkungen
Vorbereitung den Ausbau
LENKER DEMONTIEREN
Scheinwerfer
1 Dekompressionszug 1 Hebelseitig demontieren.
2 Dekompressionshebel-Halterung 1
3 Kupplungszug 1 Hebelseitig demontieren.
4 Kupplungshebel-Halterung 1
5 Motorstoppschalter “ENGINE STOP” 1
6 Lichtschalter 1
7 Hauptbremszylinder 1 Siehe unter “AUSBAU”.
8 Gasseilzugkappe 1
9 Gaszug 2 1 Gasdrehgriffseitig demontieren.
10 Gaszug 1 1 Gasdrehgriffseitig demontieren.
11 Gasdrehgriff 1 Siehe unter “AUSBAU”.
12 Führungsrohr 1
13 Hülse 1
14 Lenkergriff (links) 1 Siehe unter “AUSBAU”.
15 Lenkerhalterung (oben) 2
16Lenker
1
1

GUIDON
LENKER
MANILLAR
GUIDON
Organisation de la dépose:
1
Dépose du guidon
Organisation de la dépose Ordre Nom de pièce Qté Remarques
Préparation pour la dépose
DEPOSE DU GUIDON
Phare
1 Câble de décompression 1 Déconnecter du côté levier.
2 Support du levier de décompression 1
3 Câble d’embrayage 1 Déconnecter du côté levier.
4 Support de levier d’embrayage 1
5 Bouton d’arrêt du moteur “ENGINE STOP” 1
6 Interrupteur Lumières 1
7 Maître-cylindre 1 Se reporter à “POINTS DE DEPOSE”.
8 Capuchon de câble d’accélerateur 1
9 Câble d’accélérateur 2 (serré) 1 Déconnecter du côté accélérateur.
10 Câble d’accélérateur 1 (tiré) 1 Déconnecter du côté accélérateur.
11 Poignée (droite) 1 Se reporter à “POINTS DE DEPOSE”.
12 Guide de tube 1
13 Collerette 1
14 Poignée (gauche) 1 Se reporter à “POINTS DE DEPOSE”.
15 Support de guidon (supérieur) 2
16 Guidon 1
1

MANILLAR
Alcance de la extracción:
1
Extracción del manillar
Alcance de la extracción Orden Denominación de la pieza Cantidad Observaciones
Preparación para la extracción
EXTRACCIÓN DEL MANILLAR
Faro delantero
1 Cable de descompresión 1 Desconectar en el lado de la palanca.
2 Soporte de la palanca de descompresión 1
3 Cable del embrague 1 Desconectar en el lado de la palanca.
4 Soporte de la palanca del embrague 1
5 Botón de parada del motor “ENGINE STOP” 1
6 Interruptor de las luces 1
7 Cilindro principal 1 Consulte el apartado “PUNTOS DE EXTRACCIÓN”.
8 Tapa del cable del acelerador 1
9 Cable del acelerador N˚2 (presionado) 1 Desconectar en el lado del acelerador.
10 Cable del acelerador N˚1 (flojo) 1 Desconectar en el lado del acelerador.
11 Empuñadura (derecha) 1 Consulte el apartado “PUNTOS DE EXTRACCIÓN”.
12 Guía del tubo 1
13 Casquillo 1
14 Empuñadura (izquierda) 1 Consulte el apartado “PUNTOS DE EXTRACCIÓN”.
15 Soporte del manillar (superior) 2
16Manillar
1
1

5 - 44
CHASHANDLEBAR
5. Install:
lThrottle cable cap 1
lScrew (throttle cable cap) 2
lCover (throttle cable cap) 3
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)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
8. Install:
l“ENGINE STOP” button 1
lClutch lever holder 2
lBolt (clutch lever holder) 3
lDecompressor lever holder 4
lBolt (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
CHAS
GUIDON
LENKER
MANILLAR
5. Montieren:
lGasseilzugkappe 1
lSchrauben (Gasseilzugkap-
pe) 2
lAnlaufscheibe (Gasseilzug-
kappe) 3
WARNUNG
Nach dem Festziehen der Schrau-
ben den Gasdrehgriff 4 auf
Leichtgängigkeit prüfen. Gegebe-
nenfalls das Gasdrehgriffgehäuse
erneut ausrichten und befestigen.
T R..4 Nm (0,4 m · kg)
6. Montieren:
lHauptbremszylinder 1
lHauptbremszylinder-Halte-
rung 2
lSchraube (Hauptbremszy-
linder-Halterung) 3
HINWEIS:
lDie Halterung mit nach oben ge-
richteter Pfeilmarkierung a ein-
bauen.
lZuerst die oberen, dann die unte-
ren Halterungsschrauben festzie-
hen.
7. Einbauen:
lLichtschalter 1
T R..9 Nm (0,9 m · kg)
T R..2 Nm (0,2 m · kg)
8. Montieren:
lMotorstoppschalter “ENGI-
NE STOP” 1
lKupplungshebel-Halterung
2
lSchraube (Halterung) 3
lDekompressionshebel-Hal-
terung 4
lSchraube (Dekompressi-
onshebel-Halterung) 5
lKabelbinder 6
T R..4 Nm (0,4 m · kg)
T R..4 Nm (0,4 m · kg)
5. Monter:
lCapuchon de câble d’accéléra-
teur 1
lVis (capuchon de câble d’accé-
lérateur) 2
lCache (capuchon de câble
d’accélérateur) 3
AVERTISSEMENT
Après avoir serré les vis, vérifier que
la poignée des gaz 4 tourne sans pro-
blème. Sinon resserrer les boulons
pour la régler.
T R..4 Nm (0,4 m · kg, 2,9 ft · lb)
6. Monter:
lMaître-cylindre 1
lDemi-palier de fixation de maî-
tre-cylindre 2
lBoulon (demi-palier de fixation)
3
N.B.:
lReposer la support pour que la flèche
a soit dirigée vers le haut.
lSerrer d’abord le boulon sur le côté
supérieur du demi-palier de fixation de
maître-cylindre, puis serrer le boulon
sur le côté inférieur.
7. Posér:
lL’interrupteur lumières 1
T R..9 Nm (0,9 m · kg, 6,5 ft · lb)
T R..2 Nm (0,2 m · kg, 1,4 ft · lb)
8. Monter:
lBouton d’arrêt du moteur
“ENGINE STOP” 1
lSupport de levier d’embrayage
2
lBoulon (support de levier
d’embrayage) 3
lSupport du levier de décom-
presseur
4
lBoulon (support du levier de
décompresseur) 5

lBride 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. Instalar:
lTapa del cable del acelerador
1
lTornillo (tapa del cable del ace-
lerador) 2
lCubierta (tapa del cable del
acelerador) 3
ADVERTENCIA
Después de apretar los tornillos, com-
pruebe que la empuñadura del acele-
rador 4 se mueva suavemente. Si no
es así, vuelva a apretar los pernos para
realizar el ajuste.
T R..4 Nm (0,4 m · kg, 2,9 ft · lb)
6. Instalar:
lCilindro principal 1
lMénsula del cilindro principal
2
lPerno (ménsula del cilindro
principal) 3
NOTA:
lInstale la ménsula de form a que la
flecha esté hacia arriba.
lApriete en primer lugar el perno de la
parte superior de la ménsula del cilin-
dro principal y después apriete el
perno de la parte inferior.
7. Instalar:
lInterruptor de las luces 1
T R..9 Nm (0,9 m · kg, 6,5 ft · lb)
T R..2 Nm (0,2 m · kg, 1,4 ft · lb)
8. Instalar:
lBotón de parada del motor
“ENGINE STOP” 1
lSoporte de la palanca del
embrague 2
lPerno (soporte de la palanca
del embrague) 3
lSoporte de la palanca del des-
compresor 4
lPerno (soporte de la palanca
del descompresor) 5
lAbrazadera 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 - 45
CHASHANDLEBAR
NOTE:
lThe “ENGINE STOP” button, clutch lever
holder, decompression lever holder and
clamp should be installed according to the
dimensions shown.
lPass the “ENGINE STOP” button lead in the
middle of the clutch holder.
9. Install:
lClutch cable 1
lDecompression cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and decompression cable
end.
10. Adjust:
lClutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
lDecompression lever free play
Refer to “DECOMPRESSION LEVER
ADJUSTMENT” section in the CHAP-
TER 3.
B
2
1
11. Insert the end of the fuel breather hose
1 into the hole of the steering shaft.