2000 YAMAHA WR 400F fuel

1 - 14
GEN
INFO
STARTING AND BREAK-IN
6. Pull the decompression lever to the han-
dlebar and depress the kick starter 10 ~
30˚.
7. Release the decompression lever and
return the kick starter to its original posi-
tion and then kick the kick starter.
WARNING
Do not open the throttle while kicking the
kick starter. Otherwise, the kick starter may
kick back.
8. Return the cold starter knob to its original
position and run the engine at 3,000 ~
5,000 r/min for 1 or 2 minutes.
NOTE:
Since this model is equipped with an accelera-
tor pump, if the engine is raced (the throttle
opened and closed), the air/fuel mixture will be
too rich and the engine may stall. Also unlike a
two-stroke engine, this model can idle.
CAUTION:
Do not warm up the engine for extended
periods of time.

1 - 16
GEN
INFO
EC194001
BREAK-IN PROCEDURES
1. Before starting the engine, fill the fuel
tank with the fuel.
2. Perform the pre-operation checks on the
machine.
3. Start and warm up the engine. Check the
idle speed, and check the operation of
the controls and the “ENGINE STOP”
button. Then, restart the engine and
check its operation within no more than 5
minutes after it is restarted.
4. Operate the machine in the lower gears
at moderate throttle openings for five to
eight minutes.
5. Check how the engine runs when the
motorcycle is ridden with the throttle 1/4
to 1/2 open (low to medium speed) for
about one hour.
6. Restart the engine and check the opera-
tion of the machine throughout its entire
operating range. Restart the machine
and operate it for about 10 to 15 more
minutes. The machine will now be ready
to race.
CAUTION:
lAfter the break-in or before each race,
you must check the entire machine for
loose fittings and fasteners as per
“TORQUE-CHECK POINTS”.
Tighten all such fasteners as required.
lWhen any of the following parts have
been replaced, they must be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in operation is
necessary.
PISTON, RING, VALVES, CAMSHAFTS
AND GEARS:
These parts require about 30 minutes of
break-in operation at half-throttle or less.
Observe the condition of the engine care-
fully during operation.
STARTING AND BREAK-IN

1 - 17
GEN
INFO
TORQUE-CHECK POINTS
EC1A0012
TORQUE-CHECK POINTS
Frame construction
Combined seat and tank
Engine mounting
Steering Steering shaft to
handlebar
Suspension Front Steering shaft to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to rear frame
Fuel tank to frame
Silencer to rear frame
Frame to engine
Steering shaft to frame
Steering shaft to handle crown
Handle crown to handlebar
Front fork to handle crown
Front fork to under bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of front axle
Tightening of axle holder
Tightening of rear axle
Wheel to sprocket
Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Brake disc to wheel
Tightening of union bolt
Master cylinder to frame
Tightening of air bleeder
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

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GEN
INFO
CLEANING AND STORAGE
EC182001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the car-
buretor float bowl.
2. Remove the spark plug, pour a table-
spoon of SAE 10W-30 motor oil in the
spark plug hole, and reinstall the plug.
With the engine stop switch pushed in,
kick the engine over several times to coat
the cylinder walls with oil.
3. Remove the drive chain, clean it thor-
oughly with solvent, and lubricate it. Rein-
stall the chain or store it in a plastic bag
tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid
or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do
not apply oil to rubber parts or the seat
cover.
NOTE:
Make any necessary repairs before the
machine is stored.

2 - 1
SPEC

GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: WR400F (EUROPE)
WR400FM (USA)
WR400F(M) (CDN, AUS, NZ, ZA)
Model code number: 5GS5 (USA)
5GS6 (EUROPE)
5GS8 (CDN, AUS, NZ, ZA)
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 122.0 kg (270 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
[For USA and CDN]
At 5 ˚C (40 ˚F) or higher

Yamalube 4 (20W-
40) or SAE 20W-40 type SH motor oil (Non-
Friction modified)
At 15 ˚C (60 ˚F) or lower
õ
Yamalube 4 (10W-
30) or SAE 10W-30 type SH motor oil (Non-
Friction modified) and/or Yamalube 4-R (15W-
50) (Non-Friction modified)
[Except for USA and CDN]
API “SH” or higher grade
(Designed primarily for motorcycles)
-20
-4-10
140
3010
5020
6830
8640 50
104
122¡CTemp.
¡F
10W/30
10W/40
20W/40
20W/50

2

2 - 2
SPEC

GENERAL SPECIFICATIONS
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
Fuel:
Type Premium unleaded fuel with a research octane
number of 95 or higher. (Except for AUS)
Unleaded fuel only (For AUS)
Tank capacity 12 L (2.64 Imp gal, 3.17 US gal)
(For USA, CDN)
Reserve 8 L (1.76 Imp gal, 2.11 US gal)
(Except for USA, CDN)
1.6 L (0.35 Imp gal, 0.42 US gal)
(For USA, CDN)
1.4 L (0.31 Imp gal, 0.37 US gal)
(Except for USA, CDN)
Carburetor:
Type FCR-MX39
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK
U24ESR-N/DENSO
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 62/21 (2.952)
Secondary reduction system Chain drive
Secondary reduction ratio 50/14 (3.571)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 29/12 (2.416)
2nd 26/15 (1.733)
3rd 21/16 (1.312)
4th 21/20 (1.050)
5th 21/25 (0.840)
Chassis:
Frame type Semi double cradle
Caster angle 27.8˚
Trail 123 mm (4.84 in)
2

2 - 16
SPECMAINTENANCE SPECIFICATIONS
HINWEIS: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 reservoir tank and frame M6 ´ 1.0 1 10 1.0 7.2
Rear brake hose union bolt (caliper) M10 ´ 1.25 1 30 3.0 22
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
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 26 2.6 19
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 4 0.4 2.9
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 mounting (For USA, CDN) M6 ´ 1.0 6 4 0.4 2.9
Air scoop and fuel tank
(For EUROPE, AUS, NZ, ZA)M6 ´ 1.0 4 4 0.4 2.9
Air scoop and radiator panel (lower)
(For EUROPE, AUS, NZ, ZA)M6 ´ 1.0 2 4 0.4 2.9
Rear fender mounting M6 ´ 1.0 4 7 0.7 5.1
Number plate M6 ´ 1.0 3 7 0.7 5.1
Coolant reservoir tank M6 ´ 1.0 2 7 0.7 5.1

2 - 21
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.
‚
Pass the “ENGINE STOP” but-
ton lead, regulator lead and
lights switch lead along the
inner and side of the decom-
pression cable.
ë
Fasten the CDI magneto lead,
neutral switch lead “ENGINE
STOP” button lead and lights
switch lead to the frame with a
plastic locking tie.äPass the “ENGINE STOP”
button lead and lights switch
lead along the inner side of
the oil tank breather hose.
ìFasten the sub wire harness,
“ENGINE STOP” button lead
and lights switch lead to the
frame with a plastic locking
tie.
íPass the cylinder head
breather hose along the right
side of the oil tank breather
hose.
îFasten the sub wire harness
to the frame with a plastic
locking tie and cut off the tie
end.
éFasten the TPS lead (in the
sub wire harness) under the
frame.