2000 YAMAHA WR 400F maintenance

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 - 17
SPECMAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
C.D.I.:
Magneto-model/manufacturer F5BF/YAMAHA ----
Source coil 1 resistance (color) 640 ~ 960 W at 20 ˚C (68 ˚F)
(Green – Brown)----
Source coil 2 resistance (color) 464 ~ 696 W at 20 ˚C (68 ˚F)
(Green – Pink)----
Lighting coil resistance (color) 0.16 ~ 0.24 W at 20 ˚C (68 ˚F)
(Black – Yellow)
Pickup coil resistance (color) 248 ~ 372 W at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5GS/YAMAHA ----
Ignition coil:
Model/manufacturer JF2/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.20 ~ 0.30 W at 20 ˚C (68 ˚F) ----
Secondary winding resistance 9.5 ~ 14.3 kW at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 ´ 1.0 3 10 1.0 7.2
Rotor M10 ´ 1.25 1 48 4.8 35
Ignition coil M6 ´ 1.0 2 7 0.7 5.1

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
EC310022
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks
ENGINE OIL
Replace
cc
OIL FILTER
Replace
cc
VALVES
Check the valve clearances.
Inspect
Replace
cc
c
c
The engine must be cold.
Check the valve seats and
valve stems for wear.
VALVE SPRINGS
Inspect
Replace
c
c
Check the free length and
the tilt.
VALVE LIFTERS
Inspect
Replace
c
c
Check for scratches and
wear.
CAMSHAFTS
Inspect
Replace
c
c
Inspect the camshaft sur-
face.
CAMSHAFT SPROCKETS
Inspect
Replace
c
c
Check for wear on the
teeth and for damage.
PISTON
Inspect
Clean
Replace
cc
c
c
Inspect crack
Remove carbon
PISTON RING
Inspect
Replace
c
cc
Check ring end gap
PISTON PIN
Inspect
Replace
c
c
CYLINDER HEAD
Inspect and clean
c
Remove carbon
Change gasket
CYLINDER
Inspect and clean
Replace
c
c
Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
cc
c
Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Inspect
Replace bearing
c
c
3

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
c
Inspect wear
ROTOR NUT
Retighten
cc
MUFFLER
Inspect
Clean
Replace
Retighten
cc
ccc
*Whichever comes first
CRANK
Inspect and clean
cc
CARBURETOR
Inspect, adjust and clean
cc
When using a high-pres-
sure washer, make sure
that water does not enter
the accelerator pump.
SPARK PLUG
Inspect and clean
Replace
cc
c
DRIVE CHAIN
Lubricate, slack, alignment
Replace
cc
c
Use chain lube
Chain slack: 40 ~ 50 mm
(1.6 ~ 2.0 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
cc
cc
c
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
cc
Refer to “STARTING AND
BREAK-IN” section in the
CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
cc
c
Use foam air-filter oil
OIL STRAINER (frame)
Clean
c
FRAME
Clean and inspect
cc
FUEL TANK, COCK
Clean and inspect
cc
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
c
c
c
c
cc
c
c
c
c
c
c
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
c
cc
c
c
Suspension oil “01” ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks
3

3 - 3
INSP
ADJ

MAINTENANCE INTERVALS
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
cc
Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube and retighten
c
cc
c
Lithium base grease
CHAIN GUARD AND ROLLERS
Inspect
cc
SWINGARM
Inspect and retighten
cc
RELAY ARM, CONNECTING ROD
Inspect and lube
cc
Lithium base grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
cc
c
c
Lithium base grease
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate
c
cc
c
c
cc
Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Lubricate
c
cc
c
Yamaha cable lube or
SAE 10W-30 motor oil ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks

3 - 4
INSP
ADJ

PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator filler cap.
Check that the coolant level is correct in the coolant reservoir
tank.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-12
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-13 ~ 17
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-25 ~ 31
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-32 ~ 34
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-42 ~ 43
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-43 ~ 44
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-34 ~ 41
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-2
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-32
Lubrication Check for smooth operation. Lubricate if necessary. P.3-45
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-17
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-5
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 21

3 - 11
INSP
ADJDECOMPRESSION LEVER ADJUSTMENT/
AIR FILTER CLEANING
2. Apply:
lLithium soap base grease
On the throttle cable end a.
3. Install:
lThrottle cable cap
DECOMPRESSION LEVER ADJUSTMENT
1. Check:
lDecompression lever free play
2. Adjust:
lDecompression lever free play
EC35G040
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.Checking steps:
lRemove the timing plug.
lTurn the crankshaft counterclockwise to
align the T.D.C. mark a on the rotor with
the align mark b on the crankcase cover
when piston is at T.D.C. on compression
stroke.
lCheck the free play c.
Free play:
5 ~ 9 mm (0.20 ~ 0.35 in)
Adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 2 in or out until the
adjustment is suitable.
lTighten the locknut.
CAUTION:
After the adjustment, start the engine
and make sure that the engine does not
stop when the handlebars are turned
fully both ways. If the decompression
cable is too tense, the engine will stop
by the decompression system.