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

2 - 18
SPECGENERAL SPECIFICATIONS (WR400F)
EC211000
GENERAL SPECIFICATIONS (WR400F)
Model name: WR400F (EUROPE)
WR400FN (AUS)
Model code number: 5GS9
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 121.5 kg (268 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
API “SH” or higher grade
Oil capacity:
Engine oil
Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt)
With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt)
Total amount 1.7 L (1.50 Imp qt, 1.80 US qt)
Coolant capacity (including all routes): 1.2 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
-20
-4-10
140
3010
5020
6830
8640 50
104
122¡CTemp.
¡F
10W-30
10W-40
20W-40
20W-50
15W-40

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
MAINTENANCE SPECIFICATIONS (WR400F)
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size 92.00 ~ 92.01 mm
(3.6220 ~ 3.6224 in)----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (left) ----
Camshaft cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)----
Camshaft bearing diameter 21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)----
Camshaft-to-cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)0.08 mm
(0.003 in)
Cam dimensions
Intake “A” 31.7 ~ 31.8 mm
(1.248 ~ 1.252 in)31.6 mm
(1.244 in)
“B” 22.95 ~ 23.05 mm
(0.9035 ~ 0.9075 in)22.85 mm
(0.900 in)
Exhaust “A” 31.2 ~ 31.3 mm
(1.2283 ~ 1.2323 in)31.1 mm
(1.224 in)
“B” 22.95 ~ 23.05 mm
(0.9035 ~ 0.9075 in)22.85 mm
(0.900 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
A
B

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
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)0.6 mm
(0.024 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 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)0.9 mm
(0.035 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 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

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
Clutch:
Friction plate 1 thickness 2.72 ~ 2.88 mm
(0.107 ~ 0.113 in)2.52 mm
(0.099 in)
Inner diameter ø112 mm (4.41 in) ----
Quantity 7 ----
Friction plate 2 thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.72 mm
(0.107 in)
Inner diameter ø116 mm (4.57 in) ----
Quantity 1 ----
Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ----
Quantity 7 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 44 mm (1.73 in) 43 mm
(1.69 in)
Quantity 5 ----
Clutch housing thrust clearance 0.20 ~ 0.45 mm
(0.0079 ~ 0.0177 in)----
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kick starter:
Type Ratchet type ----
Carburetor:
I. D. mark 5GS6 61 ----
Main jet (M.J) #165 ----
Main air jet (M.A.J) #200 ----
Jet needle-clip position (J.N) OBDRQ-4 ----
Cutaway (C.A) 1.5 ----
Pilot jet (P.J) #42 ----
Pilot air jet (P.A.J) #75 ----
Pilot outlet (P.O) ø0.9 ----
Pilot screw (example) (P.S) 1-1/2 ----
Bypass (B.P) ø1.0 ----
Valve seat size (V.S) ø3.8 ----
Starter jet (G.S) #65 ----
Float height (F.H) 8 mm (0.31 in) ----
Engine idle speed 1,700 ~ 1,900 r/min ----
Intake vacuum 33.3 ~ 38.7 kPa
(250 ~ 290 mmHg, 9.84 ~ 11.42 inHg)---- Item Standard Limit

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S ´ 1.0 1 13 1.3 9.4
Camshaft cap M6 ´ 1.0 10 10 1.0 7.2
Cylinder head (stud bolt) M6 ´ 1.0 2 7 0.7 5.1
M8 ´ 1.25 3 15 1.5 11
(bolt) M10 ´ 1.25 4 44 4.4 32
(nut) M6 ´ 1.0 2 10 1.0 7.2
M8 ´ 1.25 2 20 2.0 14
Cylinder head cover M6 ´ 1.0 2 10 1.0 7.2
Cylinder M6 ´ 1.0 1 10 1.0 7.2
Timing chain tensioner M6 ´ 1.0 2 10 1.0 7.2
Tensioner cap bolt M6 ´ 1.0 1 7 0.7 5.1
Timing chain guide (rear) M6 ´ 1.0 2 10 1.0 7.2
Decompression shaft M6 ´ 1.0 1 7 0.7 5.1
Decompression cable guide M6 ´ 1.0 1 10 1.0 7.2
Exhaust pipe (nut) M8 ´ 1.25 1 13 1.3 9.4
(bolt) M8 ´ 1.25 1 24 2.4 17
Silencer M8 ´ 1.25 2 35 3.5 25
Silencer clamp M8 ´ 1.25 1 20 2.0 14
Exhaust pipe protector M6 ´ 1.0 3 10 1.0 7.2
Spark arrester (for USA) M6 ´ 1.0 3 10 1.0 7.2
Silencer end pipe (for USA) M6 ´ 1.0 1 10 1.0 7.2
Clamp (air cleaner joint) M5 ´ 0.8 1 3 0.3 2.2
Clamp (carburetor joint) M4 ´ 0.7 1 3 0.3 2.2
Air filter joint clamp M6 ´ 1.0 1 3 0.3 2.2
Throttle cable cover M5 ´ 0.8 1 4 0.4 2.9
Air filter element M6 ´ 1.0 1 2 0.2 1.4
Air filter case cover M6 ´ 1.0 4 4 0.4 2.9
Radiator panel (upper) M6 ´ 1.0 2 10 1.0 7.2
Radiator M6 ´ 1.0 6 10 1.0 7.2
Radiator hose clamp M6 ´ 1.0 8 2 0.2 1.4
Impeller M8 ´ 1.25 1 14 1.4 10
Water pump housing cover M6 ´ 1.0 3 10 1.0 7.2
Coolant drain bolt M6 ´ 1.0 1 10 1.0 7.2
Oil pump cover M5 ´ 0.8 1 4 0.4 2.9
Oil pump M6 ´ 1.0 3 10 1.0 7.2
Engine oil drain bolt (oil filter) M6 ´ 1.0 1 10 1.0 7.2
Oil filter cover M6 ´ 1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10 ´ 1.25
M8 ´ 1.251
220
182.0
1.814
13
Oil hose clamp — 2 2 0.2 1.4
Clutch cover M6 ´ 1.0 7 10 1.0 7.2
Crankcase cover (right) M6 ´ 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 ´ 1.0 8 10 1.0 7.2
Crankcase M6 ´ 1.0 12 12 1.2 8.7

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Rear brake hose union bolt (master cylinder)M10 ´ 1.25 1 30 3.0 22
Rear wheel axle and nut M20 ´ 1.5 1 125 12.5 90
Driven sprocket and wheel hub M8 ´ 1.25 6 42 4.2 30
Nipple (spoke) — 72 3 0.3 2.2
Disc cover and rear brake caliper M6 ´ 1.0 2 7 0.7 5.1
Protector and rear brake caliper M6 ´ 1.0 2 7 0.7 5.1
Engine mounting:
Engine bracket and frame M8 ´ 1.25 7 34 3.4 24
Engine and frame (front) M10 ´ 1.25 1 69 6.9 50
Engine and frame (upper) M10 ´ 1.25 1 55 5.5 40
Engine and frame (lower) M10 ´ 1.25 1 69 6.9 50
Engine guard (left and right) M8 ´ 1.25 2 23 2.3 17
Pivot shaft and nut M16 ´ 1.5 1 85 8.5 61
Relay arm and swingarm M14 ´ 1.5 1 80 8.0 58
Relay arm and connecting rod M14 ´ 1.5 1 80 8.0 58
Connecting rod and frame M14 ´ 1.5 1 80 8.0 58
Rear shock absorber and frame M10 ´ 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 ´ 1.25 1 53 5.3 38
Rear frame and frame M8 ´ 1.25 3 29 2.9 21
Swingarm and brake hose holder M5 ´ — 4 4 0.4 2.9
Drive chain tensioner mounting M8 ´ 1.25 2 19 1.9 13
Chain support and swingarm M6 ´ 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 ´ 0.8 4 6 0.6 4.3
Fuel tank mounting M6 ´ 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 ´ 1.0 2 7 0.7 5.1
Fuel tank and seat set bracket M6 ´ 1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M6 ´ 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 ´ 1.0 4 7 0.7 5.1
Seat mounting M8 ´ 1.25 2 23 2.3 17
Side cover mounting M6 ´ 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 ´ 1.0 4 4 0.4 2.9
Air scoop and radiator panel (lower) M6 ´ 1.0 2 4 0.4 2.9
Front fender mounting M6 ´ 1.0 4 7 0.7 5.1
Rear fender mounting M6 ´ 1.0 4 7 0.7 5.1
Headlight stay (under) and under bracket M6 ´ 1.0 2 7 0.7 5.1
Headlight M6 ´ 1.0 3 7 0.7 5.1
Tail light M6 ´ 1.0 3 4 0.4 2.9
Tail light lead clamp and rear fender M4 ´ 1.59 2 1 0.1 0.7
Coolant reservoir tank M6 ´ 1.0 2 7 0.7 5.1
Sidestand bracket and frame M10 ´ 1.25 2 64 6.4 46
Sidestand mounting M10 ´ 1.25 1 64 6.4 46

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SPEC
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE SPECIFICA-
TION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg ´ m/sec
2 Force
Nm
m • kgNewton meter
Meter kilogramN ´ m
m ´ kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute — Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

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SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Hose guide
2
Brake hose
3
Regulator
4
Fuel tank breather hose
5
Oil tank breather hose
6
Clamp
7
“ENGINE STOP” button lead
8
Sub wire harness
9
Tail light lead
0
TPS (throttle position sensor) lead
A
Neutral switch lead
B
Oil hose
C
Cylinder head breather hose
D
CDI magneto lead
E
Hose holder
F
Clutch cable
G
Decompression cable
H
Lights switch lead
I
Carburetor breather hose
J
Overflow hose
K
Coolant reservoir tank breather hose

Pass the fuel tank breather
hose behind handlebar, then
insert it into the steering shaft
hole.
õ
Pass the decompression
cable, “ENGINE STOP” but-
ton lead and lights switch lead
under where the oil hose is
attached.
‚
Fasten the CDI magneto lead,
neutral switch lead “ENGINE
STOP” button lead and lights
switch lead to the frame with a
plastic locking tie.
ë
Pass the “ENGINE STOP” but-
ton lead and lights switch lead
along the inner side of the oil
tank breather hose.
ä
Fasten the sub wire harness,
“ENGINE STOP” button lead
and lights switch lead to the
frame in front of the protector
of the sub wire harness with a
plastic locking tie and cut off
the tie end.
ì
Pass the cylinder head
breather hose along the right
side of the oil tank breather
hose.
í
Fasten the sub wire harness
and “ENGINE STOP” button
lead to the frame with a plas-
tic locking tie and cut off the
tie end.
î
Pass the sub wire harness
between the engine brackets.

SPEC

2 - 38
CHEMINEMENT DES CABLES
KABELFÜHRUNG
DIAGRAMA DE RUTA DE CABLES
KABELFÜHRUNG
1
Kabelführung
2
Bremsschlauch
3
Regler
4
Kraftstofftank-Belüftungsschlauch
5
Öltank-Belüftungsschlauch
6
Kabelbinder
7
Motorstoppschalter-Kabel
8
Nebenkabelsatz
9
Rücklicht
0
Drosselklappensensor-Kabel
A
Leerlaufschalter-Kabel
BÖlschlauch
CZylinderkopf-Entlüftungsschlauch
DCDI-Schwungradmagnetzünder-Ka-
bel
ESchlauchhalterung
FKupplungszug
GDekompressionszug
HLichtschalterleitung
IVergaser-Entlüftungsschlauch
JAuslaufschutzschlauch
KKühlmittelausgleichstank-Lüftungs-
schlauch
Den Kraftstofftank-Belüftungs-
schlauch zwischen Lenker und
Zugstrebe führen und das Ende durch
die Bohrung im Nummerschild führen.
õDen Dekompressionszug hinter dem
Öltank-Belüftungsschlauch und über
das Öltankrohr führen.
‚Das CDI-Schwungradmagnetzünder-
Kabel, Leerlaufschalter-Kabel und
Motorstoppschalter-Kabel mit wieder-
verwenden. Kabelbinder am Rahmen
befestigen.
ëDas Motorstoppschalter-Kabel hinter
dem Öltank-Belüftungsschlauch füh-
ren.
äDen Nebenkabelbaum das Motor-
stoppschalter-Kabel und das Licht-
schalterkabel mit. Kabelbinder am
Rahmen befestigen und das Binde-
rende abschneiden.
ìDen Zylinderkopf-Entlüftungsschlauch
rechts vom Öltank-Belüftungs-
schlauch führen.
íDen Nebenkabelbaum und die Motor-
stoppschalterleitung mit einem Kabel-
binder am Rahmen befestigen und
das überstehende Kabelbinderende
abschneiden.
îDen Nebenkabelsatz zwischen den
Motorlagern hindurchführen.
CHEMINEMENT DES
CABLES
1Guide de flexible
2Tuyau de frein
3Régulateur
4Reniflard de réservoir d’essence
5Reniflard de réservoir d’huile
6Bride
7Fil de bouton d’arrêt du moteur
“ENGINE STOP”
8Faisceau de fils secondaires
9Fil de feux arrière
0Fil de TPS (copteur du papillon d’accélé-
ration)
AFil de contacteur de point mort
BFlexible d’huile
CReniflard de culasse
DFil de magnéto CDI
ESupport de flexible
FCâble d’embrayage
GCâble du décompresseur
HFil de commutateur de feux
IReniflard de carburateur
JFlexible de trop-plein
KFlexible de reniflard du réservoir de
liquide de refroidissement
Faire passer le flexible de reniflard du
réservoir d’essence derrière le guidon,
puis l’insérer dans le trou de l’axe de la
colonne de direction.
õFaire passer le câble de décompression, le
fil de bouton d’arrêt du moteur “ENGINE
STOP” et le fil de commutateur de feux
sous l’endroit où le flexible d’huile est
attaché.
‚Attacher le fil de magnéto CDI, le fil de
commutateur de point mort, le fil du bou-
ton d’arrêt du moteur “ENGINE STOP”
et le fil de commutateur de feux au cadre
à l’aide d’une attache en plastique.
ëFaire passer le fil de bouton d’arrêt du
moteur “ENGINE STOP” et le fil de com-
mutateur de feux le long du côté intérieur
du flexible de reniflard du réservoir
d’huile.
äAttacher le faisceau de fils secondaires, le
fil de bouton d’arrêt du moteur “ENGINE
STOP” et le fil de commutateur de feux
au cadre devant la protection du faisceau
de fils secondaires à l’aide d’une attache
en plastique et couper l’extrémité de
l’attach.
ìFaire passer le reniflard de culasse le long
du côté droit du reniflard du réservoir
d’huile.
íAttacher le faisceau de fils secondaires et
le fil de bouton d’arrêt du moteur
“ENGINE STOP” au cadre à l’aide d’une
attache en plastique et couper l’extrémité
de celle-ci.
îFaire passer le faisceau de fils secondaire
par les supports du moteur.
DIAGRAMA DE RUTA DE
CABLES
1Guía del tubo
2Tubo del freno
3Regulador
4Tubo respiradero del depósito de combus-
tible
5Tubo respiradero del depósito de aceite
6Abrazadera
7Cable del botón de parada del motor
“ENGINE STOP”
8Sub-cableado
9Cable de la luz trasera
0Cable TPS (sensor de posición del acele-
rador)
ACable del interruptor de punto muerto
BTubo de aceite
CTubo respiradero de la culata
DCable del magneto CDI
ESoporte del tubo
FCable del embrague
GCable de descompresión
HCable del interruptor de las luces
ITubo respiradero del carburador
JTubo de desbordamiento
KTubo respiradero del depósito de reserva
del refrigerante
Pasar el tubo respiradero del depósito de
combustible por detrás del manillar y des-
pués insertarlo en del orificio del eje de la
dirección.
õPasar el cable de descompresión, el cable
del botón de parada del motor “ENGINE
STOP” y el cable del interruptor de las
luces por debajo de la zona de colocación
del tubo de aceite.
‚Sujetar el cable del magneto CDI, el cable
del interruptor de punto muerto, el cable
del botón de parada del motor “ENGINE
STOP” y el cable del interruptor de las
luces al bastidor mediante una conexión
plástica de cierre.
ëPasar el cable del botón de parada del
motor “ENGINE STOP” y el cable del
interruptor de las luces por la parte interna
lateral del tubo respiradero del depósito
de aceite.
äSujetar el sub-cableado, el cable del botón
de parada del motor “ENGINE STOP” y
el cable del interruptor de las luces al bas-
tidor delante del protector del sub-
cableado con una conexión plástica de
cierre y corte el extremo de la conexión
plástica.
ìPasar el tubo respiradero de la culata por
el lado derecho del tubo respiradero del
depósito de aceite.
íSujetar el sub-cableado y el cable del
botón de parada del motor “ENGINE
STOP” al bastidor con una conexión plás-
tica de cierre y corte el extremo de la
conexión plástica.
îPasar el sub-cableado entre las ménsulas
del motor.

2 - 41
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Lights switch
3Lights switch lead
4Clamp
5Decompression cable
6Clutch cable
7Hose guide
8Trip meter
9Brake hose
0“ENGINE STOP” button leadFasten the “ENGINE STOP” button lead to the handlebar with the
plastic band.
õPass the decompression cable between the brake hose and clutch
cable.
‚Pass the throttle cables between the handle crown and trip meter.
ëPass the light switch leads behind the “ENGINE STOP” button lead,
then pass the head light lead (of the light switch leads) in front of the
head pipe.
äInstall the trip meter cable so that its bent portion faces the chassis
rear.
ìInstall the brake hose so that it contacts the master cylinder projec-
tion and that its bent portion faces downward.