2001 YAMAHA WR 400F lock

2 - 38
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.

2 - 39
SPEC

CABLE ROUTING DIAGRAM
é
Fasten the TPS lead (in the
sub wire harness) under the
frame so that it does not con-
tact the carburetor.
ï
Fasten the TPS lead under the
coupler to the frame with a
plastic locking tie.
ð
Pass the carburetor breather
hose and overflow hose
between the connecting rod
and cross tube (frame).
ñ
Fasten the neutral switch lead
and oil hose together with a
plastic locking tie.
÷
Fasten the neutral switch lead
to the frame with a plastic
band.
öFasten the cylinder head
breather hose with the hose
holder.¯Fasten the neutral switch lead
and CDI magneto lead
together with a plastic band.
¸Pass the clutch cable through
the cable guide.
ÎPass the cylinder head
breather hose along the inner
side of the radiator pipe.
åPass the clutch cable between
the frame and radiator and
over the lower boss on the
radiator.
êPass the neutral switch lead
and CDI magneto lead over
the middle radiator mounting
boss. Then, pass the decom-
pression cable under the mid-
dle radiator mounting boss
and along the left side of the
neutral switch lead and CDI
magneto lead.æPass the clutch cable through
the cable guide.
èFit the brake hose into the
guide on the protector.
×Fasten the ignition coil lead
(in the sub wire harness) on
the upper inside of the frame
and cut off the tie end.
ãPass the ignition coil lead (in
the sub wire harness) under
the cushion bracket (frame).
ÅFasten the ignition coil lead
(in the sub wire harness) to
the frame with a plastic lock-
ing tie and cut off the tie end.
çPass the carburetor breather
hoses and overflow hose so
that all there hoses do not
contact the rear shock
absorber.

2 - 40
SPECCABLE ROUTING DIAGRAM
1Coolant reservoir tank
breather hose
2Clamp
3Ignition coil
4High tension cord
5CDI unit
6CDI unit band
7Radiator (left)
8Radiator (right)
9Decompression cable
0CDI unit stay (frame)Fasten the coolant reservoir tank
breather hose and carburetor
breather hose together with a
plastic locking tie.
õFasten the ignition coil lead to the
frame with a plastic band.
‚Pass the ignition coil lead (in the
sub wire harness) so that it does
not contact the carburetor and
rear shock absorber and connect
it with the lead from the ignition
coil on the inside of the frame.
ëFasten the ignition coil and
ground lead to the frame with the
bolt.
äPass the throttle cables over the
high tension cord.ìPass the throttle cables along the
outer side of the CDI unit leads.
íUsing a plastic locking tie, clamp
to the frame the CDI unit leads at
their protecting tubes.
îFit the boot over the coupler.
éPass the throttle cables between
the top radiator mounting boss
and middle radiator mounting
boss.
ïPass the CDI unit leads over the
top radiator mounting boss.
ðCross the pull and return throttle
cables before the radiator.
ñPass the throttle cables through
the cable guide.
÷Insert the CDI unit band over the
CDI unit stay (frame) as far as
possible.

3 - 5
INSP
ADJ

EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING

Do not remove the radiator cap
1
, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:

Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Inspect:
l
Coolant level
Coolant level should be between the
maximum
a
and minimum
b
marks.
Coolant level is below the “LOW” level
line
®
Add soft water (tap water) up to
the proper level.
3. Start the engine and let it warm up for
several minutes.
4. Turn off the engine and check the coolant
level again.
NOTE:

Before checking the coolant level, wait a few
minutes until the coolant settles.
LOWFULLCOOLANT
a
b

COOLANT REPLACEMENT
WARNING

Do not remove the radiator cap when the
engine is hot.
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT

3 - 10
INSP
ADJCLUTCH ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
EC359020
CLUTCH ADJUSTMENT
1. Check:
lClutch lever free play a
Out of specification ® Adjust.
Clutch lever free play a:
2 ~ 4 mm (0.08 ~ 0.16 in)
2. Adjust:
lClutch lever free play
NOTE:
lMake minute adjustment on the lever side
using the adjuster 2.
lAfter adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
lLoosen the locknuts 1.
lAdjust the free play by changing their
tightening position.
lTighten the locknuts.
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
lThrottle grip free play a
Out of specification ® Adjust.
Throttle grip free play a:
3 ~ 5 mm (0.12 ~ 0.20 in)

INSP
ADJREGLAGE DE L’EMBRAYAGE/REGLAGE DES CABLES D’ACCELERATION
KUPPLUNG EINSTELLEN/GASZUGSPIEL EINSTELLEN
AJUSTE DEL EMBRAGUE/AJUSTE DEL CABLE DEL ACELERADOR
KUPPLUNG EINSTELLEN
1. Kontrollieren:
lKupplungszugspiel a
Unvorschriftsmäßig ® Ein-
stellen.
Kupplungszugspiel am
Hebeldrehpunkt a
2–4 mm
2. Einstellen:
lKupplungszugspiel
HINWEIS:
lDas Kupplungszugspiel mit der vor
dem Hebel liegenden Einstell-
schraube 2 feineinstellen.
lNach der Einstellung des Seilzug-
spiels die Funktion des Kupplungs-
hebels prüfen. Arbeitsschritte
lSicherungsmutter 1 lockern.
lDas Spiel durch Veränderung
der Befestigungsposition ein-
stellen.
lSicherungsmuttern festziehen.
GASZUGSPIEL EINSTELLEN
1. Kontrollieren:
lGaszugspiel a
Unvorschriftsmäßig ® Ein-
stellen.
Gaszugspiel am Gas-
drehgriff a
3–5 mm
REGLAGE DE L’EMBRAYAGE
1. Contrôler:
lJeu du levier d’embrayage a
Hors spécification ® Régler.
Jeu du levier d’embrayage
a:
2 à 4 mm (0,08 à 0,16 in)
2. Régler:
lJeu de levier d’embrayage
N.B.:
lFaire un réglage plus fin du côté du
levier à l’aide du dispositif de réglage
2.
lAprès le réglage, contrôler de bon
fonctionnement du levier
d’embrayage. Etapes de réglage du jeu du levier
d’embrayage:
lDesserrer le contre-écrou 1.
lRégler le jeu en modifiant leur ser-
rage.
lSerrer le contre-écrous.
REGLAGE DES CABLES D’ACCE-
LERATION
1. Vérifier:
lJeu à la poignée des gaz a
Hors spécification ® Régler.
Jeu à la poignée des gaz
a:
3 à 5 mm (0,12 à 0,20 in)
3 - 10
AJUSTE DEL EMBRAGUE
1. Comprobar:
lJuego libre de la palanca del
embrague a
Fuera de especificaciones ®
Ajustar.
Juego libre de la palanca
del embrague a:
2 ~ 4 mm (0,08 ~ 0,16 in)
2. Ajustar:
lJuego libre de la palanca del
embrague
NOTA:
lRealice un ajuste preciso en el lado de
la palanca utilizando el regulador 2.
lDespués de realizar el ajuste, com-
pruebe el correcto funcionamiento de
la palanca del embrague. Pasos de ajuste del juego libre de la
palanca del embrague:
lAfloje la contratuerca 1.
lAjuste el juego libre cambiando
sus posiciones de apriete.
lApriete las contratuercas.
AJUSTE DEL CABLE DEL ACELE-
RADOR
1. Comprobar:
lJuego libre de la empuñadura
del acelerador a
Fuera de especificaciones ®
Ajustar.
Juego libre de la empuña-
dura del acelerador a:
3 ~ 5 mm (0,12 ~ 0,20 in)

3 - 11
INSP
ADJ
THROTTLE LUBRICATION
2. Adjust:
lThrottle grip free play
Throttle grip free play adjustment steps:
lRemove the throttle cable cap 1 and
throttle cable cover 2.
NOTE:
lBefore adjusting the throttle cable free
play, the engine idle speed should be
adjusted.
lWhen the motorcycle is accelerating,
throttle cable #1 3 is pulled and throttle
cable #2 4 is pushed.
1st step:
lLoosen the locknuts 5 on throttle cable #2.
lAdjust the free play by changing their
tightening position.
2nd step:
lLoosen the locknuts 6 on throttle cable #1.
lAdjust the free play by changing their
tightening position.
lTighten the locknuts.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
lInstall the throttle cable cover and throttle
cable cap.
1
2
EC35S002
THROTTLE LUBRICATION
1. Remove:
lRubber cover 1
lThrottle cable cap 2
2. Apply:
lLithium soap base grease
On the throttle cable end a.
3. Install:
lThrottle cable cap
lScrew (throttle cable cap)
lRubber cover
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

3 - 12
INSP
ADJDECOMPRESSION LEVER ADJUSTMENT/
AIR FILTER CLEANING
DECOMPRESSION LEVER ADJUSTMENT
1. Check:
lDecompression lever free play
2. Adjust:
lDecompression lever free play
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine 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.