2001 YAMAHA WR 400F brakes

1 - 19
GEN
INFO
CLEANING AND STORAGE
FEC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good over-
all performance, and extend the life of many
components.
1. Before washing the machine, block off
the end of the exhaust pipe to prevent
water from entering. A plastic bag
secured with a rubber band may be used
for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush.
Do not apply degreaser to the chain,
sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose; use only enough pressure
to do the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a
soft towel or cloth.
6. Immediately after washing, remove
excess water from the chain with a paper
towel and lubricate the chain to prevent
rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid com-
bination cleaner-waxes, as they may con-
tain abrasives.
9. After completing the above, start the
engine and allow it to idle for several min-
utes.

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
c
Inspect wear
ROTOR NUT
Retighten
cc
MUFFLER
Inspect and retighten
Clean
Replace
cc
c
c
*Whichever comes first
*SPARK ARRESTER
Clean
(Every
six
months)
c
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 ItemAfter
break-inEvery
race
Every
third
or
500 km
(300 mi)Every
fifth
or
1,000 km
(600 mi)
As re-
quiredRemarks


3

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.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-10
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.3-26 ~ 32
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-33 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-42 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 45
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
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. —
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-33
Lubrication Check for smooth operation. Lubricate if necessary. P.3-46
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
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 ~ 22