2001 YAMAHA WR 400F transmission

ENG
4 - 94 CRANKCASE BEARING
Extent of removal:1 Crankcase bearing removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE BEARING
REMOVAL
Preparation for removal Transmission
Shift cam and shift forkRefer to “TRANSMISSION, SHIFT
CAM AND SHIFT FORK” section.
1 Oil seal 3
2 Bearing 10 Refer to “REMOVAL POINTS”.
1
CRANKCASE AND CRANKSHAFT

4 - 99
ENGCRANKCASE AND CRANKSHAFT
2. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.
3. Install:
lOil strainer 1
lBolt (oil strainer) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
4. Apply:
lSealant
On the crankcase (right) 1.
NOTE:
Clean the contacting surface of crankcase (left
and right) before applying the sealant.
5. Install:
lDowel pin 1
lO-ring 2
lCrankcase (right)
To crankcase (left).
NOTE:
lFit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft ham-
mer.
lWhen installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
New

4 - 100
ENGCRANKCASE AND CRANKSHAFT
6. Tighten:
lHose guide 1
lClutch cable holder 2
lBolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
7. Install:
lOil delivery pipe
lO-ring
lBolt (oil delivery pipe)
8. Install:
lTiming chain
lTiming chain guide (rear)
lBolt (timing chain guide)
9. Remove:
lSealant
Forced out on the cylinder mating sur-
face.
10. Apply:
lEngine oil
To the crank pin, bearing and oil deliv-
ery hole.
11. Check:
lCrankshaft and transmission operation.
Unsmooth operation ® Repair.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

ENG
4 - 100
6. Montieren:
lKabelführung 1
lKupplungszug-Halterung 2
lSchraube (Kurbelgehäuse)
HINWEIS:
Die Kurbelgehäuse-Schrauben in
stufenweise und über Kreuz festzie-
hen.
T R..12 Nm (1,2 m · kg)
7. Montieren:
lÖlzufuhrleitung
lO-Ring
lSchraube (Ölzufuhrleitung)
8. Montieren:
lSteuerkette
lSteuerkettenschiene (hin-
ten)
lSchraube (Steuerketten-
schiene)
9. Entfernen:
lDichtmittel
(von der Zylinderpaßfläche
getrieben)
10. Auftragen:
lMotoröl
(auf Kurbelzapfen, Lager
und Ölzufuhrloch)
11. Kontrollieren:
lKurbelwelle und Getriebe
(Leichtgängigkeit)
Schwergängigkeit ®
Instand setzen.
New
T R..10 Nm (1,0 m · kg)
T R..10 Nm (1,0 m · kg)
6. Monter:
lGuide de flexible 1
lSupport de câble d’embrayage
2
lBoulon (carter)
N.B.:
Serrer les boulons de serrage de carter
par étape en suivant un ordre entrecroisé.
T R..12 Nm (1,2 m · kg, 8,7 ft · lb)
7. Monter:
lTuyau d’arrivée d’huile
lJoint torique
lBoulon (tuyau d’arrivée
d’huile)
8. Monter:
lChaîne de distribution
lGuide de chaîne de distribution
(arrière)
lBoulon (guide de chaîne de
distribution)
9. Déposer:
lAgent d’étanchéité
Sorti sur la surface usinée du
cylindre.
10. Appliquer:
lHuile de moteur
Sur la goupille de carter, le rou-
lement et l’orifice de sortie
d’huile.
11. Contrôler:
lFonctionnement du vilebre-
quin et de la transmission
Fonctionnement irrégulier ®
Réparer.
New
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
6. Apretar:
lGuía del tubo 1
lSoporte del cable del embrague
2
lPerno (cárter)
NOTA:
Ajuste los pernos de apriete del cárter de
forma progresiva y entrecruzada.
T R..12 Nm (1,2 m · kg, 8,7 ft · lb)
7. Instalar:
lTubo de distribución aceite.
lJunta tórica
lPerno (rubo de distribución
aceite)
8. Instalar:
lCadena de transmisión
lGuía de la cadena de transmi-
sión (trasera)
lPerno (guía de la cadena de
distribución)
9. Extraer:
lUn producto sellante
Ejerza fuerza sobre la superfi-
cie engranada del cilindro.
10. Aplicar:
lAceite de motor
Al bulón del cárter, al cojinete
y al orificio de distribución de
aceite.
11. Comprobar:
lFuncionamiento del cigüeñal y
de la transmisión
Funcionamiento poco suave ®
Reparar.
New
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
CARTER ET VILEBREQUIN
KURBELGEHÄUSE UND KURBELWELLE
CÁRTER Y CIGÜEÑAL

ENG
4 - 101
TRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:1 Shift fork, shift cam, main axle and drive axle removal
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFT CAM
AND SHIFT FORK REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Separate the crankcase. Refer to “CRANKCASE AND CRANK-
SHAFT” section.
1 Shift fork 1 1
Refer to “REMOVAL POINTS”. 2 Shift fork 2 1
3 Shift fork 3 1
4 Shift cam 1
5 Main axle 1
6 Drive axle 1
7Collar
1
1

4 - 102
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H3000
REMOVAL POINTS
Shift fork, shaft cam and transmission
1. Remove:
lShift forks
lShift cam
lMain axle
lDrive axle
NOTE:
lTap lightly on the transmission drive axle and
shift cam with a soft hammer to remove.
lRemove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
EC4H4000
INSPECTION
EC4H4200
Gears
1. Inspect:
lMatching dog a
lGear teeth b
lShift fork groove c
Wear/damage ® Replace.
2. Inspect:
lO-ring 1
Damage ® Replace.
3. Check:
lGears movement
Unsmooth movement ® Repair or
replace.
EC4H4600
Bearing
1. Inspect:
lBearing 1
Rotate inner race with a finger.
Rough spot/seizure ® Replace.

4 - 103
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H4801
Shift fork, shift cam and segment
1. Inspect:
lShift fork 1
Wear/damage/scratches ® Replace.
2. Inspect:
lShift cam 1
lSegment 2
Bend/wear/damage ® Replace.
3. Check:
lShift fork movement
Unsmooth operation ® Replace shift
fork.
NOTE:
For a malfunctioning shift fork, replace not only
the shift fork itself but the two gears each adja-
cent to the shift fork.
ASSEMBLY AND INSTALLATION
Transmission
1. Install:
l5th pinion gear (25T) 1
l3rd pinion gear (16T) 2
lCollar 3
l4th pinion gear (20T) 4
l2nd pinion gear (15T) 5
To main axle 6.
NOTE:
lApply the molybdenum disulfide oil on the
4th and 5th pinion gears inner circumference
and on the end surface.
lApply the molybdenum disulfide oil on the
2nd and 3rd pinion gears inner circumfer-
ence.

4 - 104
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
2. Install:
l2nd wheel gear (26T) 1
l4th wheel gear (21T) 2
l3rd wheel gear (21T) 3
l5th wheel gear (21T) 4
l1st wheel gear (29T) 5
lO-ring 6
To drive axle 7.
NOTE:
lApply the molybdenum disulfide oil on the
1st, 2nd and 3rd wheel gears inner circum-
ference and on the end surface.
lApply the molybdenum disulfide oil on the
4th and 5th wheel gears inner circumfer-
ence.
lApply the lithium soap base grease on the O-
ring.
3. Install:
lPlain washer 1
lCirclip 2
NOTE:
lBe sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
lBe sure the circlip end c is positioned at
axle spline groove d.
New
4. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lWhen installing the spacer into the crank-
case, pay careful attention to the crankcase
oil seal lip.