2001 YAMAHA WR 400F lock

4 - 26
ENGCAMSHAFTS
Timing chain tensioner
1. Check:
lWhile pressing the tensioner rod lightly
with fingers, use a thin screwdriver 1
and wind the tensioner rod up fully
clockwise.
lWhen releasing the screwdriver by
pressing lightly with fingers, make sure
that the tensioner rod will come out
smoothly.
lIf not, replace the tensioner assembly.
ASSEMBLY AND INSTALLATION
1. Install:
lExhaust camshaft 1
lIntake camshaft 2
Installation steps:
lTurn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
lFit the timing chain 3 onto both camshaft
sprockets and install the camshafts on the
cylinder head.
NOTE:
The camshafts should be installed onto the
cylinder head so that the exhaust cam
sprocket punch mark c and the intake cam
sprocket punch mark d align with the sur-
face of the cylinder head.
CAUTION:
Do not turn the crankshaft during the
camshaft installation. Damage or
improper valve timing will result.

4 - 27
ENGCAMSHAFTS
2. Install:
lTiming chain tensioner
3. Turn:
lCrankshaft
Counterclockwise several turns
4. Check:
lRotor “I” mark
Align with the crankcase stationary
pointer.
lCamshaft match marks
Align with the cylinder head surface.
Out of alignment ® Adjust.
lInstall the dowel pins, clips and camshaft
caps 4.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m • kg, 7.2 ft • lb)
NOTE:
Tighten the bolts (camshaft cap) 5 in a
crisscross pattern.
CAUTION:
The bolts (camshaft cap) must be tight-
ened evenly or damage to the cylinder
head, camshaft caps and camshaft will
result.
Installation steps:
lWhile pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.
lWith the rod fully wound and the chain
tensioner UP mark a facing upward,
install the gasket 1 and the chain ten-
sioner 2, and tighten the bolt 3 to the
specified torque.
T R..
Bolt (timing chain tensioner):
10 Nm (1.0 m • kg, 7.2 ft • lb)
lRelease the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Tensioner cap bolt:
7 Nm (0.7 m • kg, 5.1 ft • lb)

4 - 50
ENGCLUTCH (WR426F)
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
lNut 1
lLock washer 2
lClutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4 to hold the clutch boss.
For USA and CDN
õExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086

õ
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
lClutch housing 1
Cracks/wear/damage ® Replace.
lClutch boss 2
Scoring/wear/damage ® Replace.
EC484201
Primary driven gear
1. Check:
lCircumferential play
Free play exists ® Replace.
lGear teeth a
Wear/damage ® Replace.
EC484400
Clutch spring
1. Measure:
lClutch spring free length a
Out of specification ® Replace springs
as a set.
Clutch spring free length:
Standard
48.4 mm (1.91 in) 47.4 mm (1.87 in)

4 - 53
ENG

CLUTCH (WR426F)
3. Install:
l
Lock washer
1

l
Nut (clutch boss)
2
NOTE:
Use the clutch holding tool 3 to hold the clutch
boss.
For USA and CDN
õExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)

õ
4. Bend the lock washer 1 tab.
5. Install:
lFriction plate 2 [d = ø119 mm (4.69 in)]
1
lClutch plate 2
NOTE:
lInstall the clutch plates and friction plates 2
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
lApply the engine oil on the friction plates and
clutch plates.
6. Install:
lBearing 1
lPlain washer 2
lCirclip 3
To push rod 1 4.
NOTE:
Apply the engine oil on the bearing and plain
washer.
New

4 - 57
ENGCLUTCH (WR400F)
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
lNut 1
lLock washer 2
lClutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4 to hold the clutch boss.
For USA and CDN
õExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
õ
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
lClutch housing 1
Cracks/wear/damage ® Replace.
lClutch boss 2
Scoring/wear/damage ® Replace.
EC484201
Primary driven gear
1. Check:
lCircumferential play
Free play exists ® Replace.
lGear teeth a
Wear/damage ® Replace.
EC484400
Clutch spring
1. Measure:
lClutch spring free length a
Out of specification ® Replace springs
as a set.
Clutch spring free length:
Standard
44 mm (1.73 in) 43 mm (1.69 in)

4 - 59
ENGCLUTCH (WR400F)
EC4A5000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
lPush lever 1
lBolt (push lever)
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lApply the engine oil on the push lever.
lFit the seat plate 2 in the groove a of the
push lever 1 and tighten the bolt (seat
plate).
2
1
a
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Clutch
1. Install:
lPrimary driven gear 1
lThrust washer 2
lClutch boss 3
NOTE:
Apply the engine oil on the primary driven gear
inner circumference.
2. Install:
lLock washer 1
lNut (clutch boss) 2
NOTE:
Use the clutch holding tool 3 to hold the clutch
boss.
For USA and CDN
õExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)

õ

4 - 60
ENGCLUTCH (WR400F)
3. Bend the lock washer 1 tab.
4. Install:
lFriction plate 1 [d = ø112 mm (4.41 in)]
1
lClutch plate 2
lFriction plate 2 [d = ø116 mm (4.57 in)]
3
NOTE:
lInstall the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate 1 and ending with a friction plate
2.
lApply the engine oil on the friction plates and
clutch plates.
5. Install:
lBearing 1
lPlain washer 2
lCirclip 3
To push rod 1 4.
NOTE:
Apply the engine oil on the bearing and plain
washer.
6. Install:
lPush rod 2 1
lPush rod 1 2
NOTE:
Apply the engine oil on the push rod 1, 2.
New
7. Install:
lPressure plate 1
NOTE:
Align the much mark a on the pressure plate
with the punched mark b on the clutch boss.

ENG
4 - 69
BALANCER
BALANCER
BALANCER
Extent of removal:1 Balancer drive gear2 Balancer
Extent of removal Order Part name Q’ty Remarks
BALANCER REMOVAL
Preparation for removal Clutch housing Refer to “CLUTCH” section.
Crankcase cover (right)Refer to “OIL FILTER, WATER PUMP AND
CRANKCASE COVER (RIGHT)” section.
Stator Refer to “CDI MAGNETO” section.
1 Nut (primary drive gear) 1
Refer to “REMOVAL POINTS”.
2 Nut (balancer) 1
3 Lock washer 1
4 Primary drive gear 1
5 Balancer drive gear 1
6 Lock washer 1
7 Balancer driven gear 1
8 Balancer 1 Refer to “REMOVAL POINTS”.
2
1
2