2000 YAMAHA WR 400F oil

4 - 92
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
5. Install:
lShift fork 1 (L) 1
lShift fork 2 (C) 2
lShift fork 3 (R) 3
lShift cam 4
To main axle and drive axle.
NOTE:
lApply the molybdenum disulfide oil on the
shift fork grooves.
lMesh the shift fork #1 (L) with the 4th wheel
gear 5 and #3 (R) with the 5th wheel gear
7 on the drive axle.
lMesh the shift fork #2 (C) with the 3rd pinion
gear 6 on the main axle.
6. Install:
lTransmission assembly 1
To crankcase (left) 2.
NOTE:
Apply the engine oil on the bearings and guide
bars.
7. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.

5 - 1
CHAS

EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR 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.
1 Trip meter cable 1
2 Hose cover 1
3 Bolt (axle holder) 4 Only loosening.
4 Nut (front wheel axle) 1
5 Front wheel axle 1
6 Front wheel 1
7 Trip meter gear unit 1
8 Collar 1
9 Oil seal 1
10 Bearing 2 Refer to “REMOVAL POINTS”.
11 Brake disk 1
WARNING
Support the machine securely so there is nodanger of it falling over.
2
31
3

5

5 - 2
CHAS

EC598100
REAR WHEEL
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Break 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.
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 disk
1
WARNING
Support the machine securely so there is nodanger of it falling over.
2
31
3

FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS

FRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:
l
Wheel
1

NOTE:

Push the wheel forward and remove the drive
chain
2
.
EC513201
Wheel bearing (if necessary)
1. Remove:
l
Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
EC594000
INSPECTION
EC514100
Wheel
1. Measure:
l
Wheel runout
Out of limit
®
Repair/replace.
2. Inspect:
l
Bearing
Rotate inner race with a finger.
Rough spot/seizure
®
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
as a set.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)

5 - 3
CHAS

ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
RUEDA DELANTERA Y RUEDA TRASERA
AUSBAU
Hinterrad
1. Demontieren:
l
Rad
1

HINWEIS:

Das Rad nach vorne stoßen und die
Antriebskette
2
abnehmen.
Radlager (nach Bedarf)
1. Demontieren:
l
Lager
1

HINWEIS:

Die Lager mit einem Lageraustreiber
2
ausbauen.
PRÜFUNG
Rad
1. Messen:
l
Felgenschlag
Unvorschriftsmäßig
®

Instand setzen/Erneuern.
Max. Felgenschlag
Höhenschlag
1
:
2,0 mm
Seitenschlag
2
:
2,0 mm
2. Kontrollieren:
l
Lager
Den inneren Laufring mit
dem Finger drehen.
Schwergängigkeit/Freßspu-
ren
®
Erneuern.
HINWEIS:

Lager, Dichtringe und Hülse im Satz
erneuern.
POINTS DE DEPOSE
Roue arrière
1. Déposer:
l
Roue
1

N.B.:

Pousser la roue vers l’avant et déposer la
chaîne de transmission
2
.
Roulement de roue (si nécessaire)
1. Déposer:
l
Roulement
1
N.B.:

Déposer le roulement en utilisant un
arrache-roulement courant 2.
CONTROLE
Roue
1. Mesure:
lVoile de roue
Hors limite ® Réparer/chan-
ger.
Limite de voile de la roue:
Radial 1: 2,0 mm
(0,08 in)
Latéral 2: 2,0 mm
(0,08 in)
2. Contrôler:
lRoulement
Faire tourner la bague inté-
rieure avec le doigt.
Point dur/grippage ® Changer.
N.B.:
Changer à la fois les roulements, la
bague d’étanchéité et la collerette de
roue.PUNTOS DE EXTRACCIÓN
Rueda trasera
1. Extraer:
lRueda 1
NOTA:
Empuje la rueda hacia delante y extraiga
la cadena de transmisión 2.
Cojinete de la rueda (en caso necesa-
rio)
1. Extraer:
lCojinete 1
NOTA:
Extraiga el cojinete con un extractor de
cojinetes universal 2.
INSPECCIÓN
Rueda
1. Medir:
lExcentricidad de la rueda
Fuera del límite ® Reparar/
reemplazar.
Límite de excentricidad de
la rueda:
Radial 1: 2,0 mm
(0,08 in)
Lateral 2: 2,0 mm
(0,08 in)
2. Inspeccionar:
lCojinete
Gire la pista interna con un
dedo.
Superficie áspera/Agarrota-
miento ® Reemplazar.
NOTA:
Reemplace los cojinetes, el retén de
aceite y el casquillo de la rueda como un
juego.

5 - 4
CHAS
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
RUEDA DELANTERA Y RUEDA TRASERA
Radachse
1. Messen:
lRadachsschlag
Unvorschriftsmäßig ®
Erneuern.
Die Meßuhr 1 verwenden.
HINWEIS:
Der Radachsschlag entspricht der
Hälfte der Meßuhranzeige.
WARNUNG
Nie versuchen, eine verbogene
Achse zu richten.
Max. Radachsschlag
0,5 mm
Bremsscheibe
1. Messen:
lBremsscheibenschlag
Die Meßuhr 1 verwenden.
Unvorschriftsmäßig ® Fel-
genschlag prüfen.
Falls im Sollbereich, die
Bremsscheibe erneuern.
2. Messen:
lBremsscheibenstärke a
Unvorschriftsmäßig ®
Erneuern.
Max. Bremsscheiben-
verzug
0,15 mm
Bremsscheiben-Min-
deststärke
Standard
Vorn 3,0 mm 2,5 mm
Hin-
ten4,0 mm 3,5 mm
Axe de roue
1. Mesurer:
lLes flexions de l’axe de roue
Hors-spécification ® Changer.
Utiliser le comparateur 1.
N.B.:
La valeur de flexion est égale à la moitié
de la lecture du comparateur.
AVERTISSEMENT
Ne jamais tenter de redresser un axe
tordu.
Limite de torsion de l’axe
de roue:
0,5 mm (0,020 in)
Disque de frein
1. Mesurer:
lDéflexion de disque de frein
Utiliser le comparateur 1.
Hors spécification ® Exami-
ner le voile de roue.
Si le voile de la roue est nor-
mal, changer le disque de frein.
2. Mesurer:
lEpaisseur de disque de frein a
Hors limite ® Changer.
Limite de déflexion de dis-
que:
0,15 mm (0,006 in)
Limite d’usure de disque:
Standard
Avant3,0 mm
(0,12 in)2,5 mm
(0,10 in)
Arriè-
re4,0 mm
(0,16 in)3,5 mm
(0,14 in)
Eje de la rueda
1. Medir:
lDeformaciones del eje de la
rueda
Fuera de especificaciones ®
Reemplazar.
Utilice el calibre de cuadrantes
1.
NOTA:
El valor de deformación se indica como
la mitad del valor de la lectura del cali-
bre de cuadrantes.
ADVERTENCIA
No intente enderezar un eje doblado.
Límite de deformación del
eje de la rueda:
0,5 mm (0,020 in)
Disco del freno
1. Medir:
lDesviación del disco del freno
Utilice el calibre de cuadrantes
1.
Fuera de especificaciones ®
Comprobar la excentricidad de
la rueda.
Si la excentricidad de la rueda
está en buen estado, reemplace
el disco del freno.
2. Medir:
lEspesor del disco del freno a
Fuera del límite ® Reempla-
zar.
Límite de desviación del
disco:
0,15 mm (0,006 in)
Límite de desgaste del
disco:
Estándar
Delan-
tero3,0 mm
(0,12 in)2,5 mm
(0,10 in)
Tra-
sero4,0 mm
(0,16 in)3,5 mm
(0,14 in)

5 - 5
CHAS

FRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
EC595100
Front wheel
1. Install:
l
Bearing (left)
1

l
Spacer
2

l
Bearing (right)
3

l
Oil seal
4

NOTE:

l
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
l
Use a socket that matches the outside diam-
eter of the race of the bearing.
l
Left side of bearing shall be installed first.
l
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
lBrake disc 1
lBolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lInstall the collar with their projection a fac-
ing the wheel.
4. Install:
lWheel
NOTE:
lInstall the brake disc between the brake
pads correctly.
lMake sure that the projections a in the trip
meter gear unit fits over the stopper b on
the front fork outer tube.

5 - 7
CHASFRONT WHEEL AND REAR WHEEL
9. Install:
lHose cover 1
lPlain washer 2
lBolt [hose cover (M8)] 3
lBolt [hose cover (M6)] 4
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
10. Install:
lTrip meter cable 11
EC525112
Rear wheel
1. Install:
lBearing (right) 1
lCirclip 2
lSpacer 3
lBearing (left) 4
lOil seal 5
NOTE:
lApply the lithium soap base grease on the
bearing and oil seal lip when installing.
lInstall the bearing with seal facing outward.
lUse a socket that matches the outside diam-
eter of the race of the bearing.
lRight side of bearing shall be installed first.
lInstall the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
New