2002 YAMAHA WR 400F fuel tank removal

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS
..................................4-1
EXHAUST PIPE AND SILENCER
.............4-2
RADIATOR
................................................4-4
CARBURETOR
..........................................4-8
CAMSHAFTS
...........................................4-22
CYLINDER HEAD
....................................4-29
VALVES AND VALVE SPRINGS
............4-33
CYLINDER AND PISTON
........................4-42
CLUTCH (WR426F)
.................................4-49
CLUTCH (WR400F)
.................................4-56
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT)
.....4-63
BALANCER
.............................................4-70
OIL PUMP
................................................4-73
KICK AXLE AND SHIFT SHAFT
.............4-77
CDI MAGNETO
........................................4-84
ENGINE REMOVAL
.................................4-88
CRANKCASE AND CRANKSHAFT
........4-93
TRANSMISSION, SHIFT CAM
AND SHIFT FORK
.................................4-102
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL
.......5-1
FRONT BRAKE AND REAR BRAKE
.....5-11
FRONT FORK
..........................................5-28
HANDLEBAR
...........................................5-41
STEERING
...............................................5-47
SWINGARM
.............................................5-53
REAR SHOCK ABSORBER
....................5-60

ENG
4 - 1
EC400000
ENGINE
EC4R0000
SEAT, FUEL TANK AND SIDE COVERS
Extent of removal:1 Seat removal2 Fuel tank removal
3 Side covers removal4 Headlight removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalSEAT, FUEL TANK AND SIDE
COVERS REMOVAL
Turn the fuel cock to “OFF”.
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Fitting band 1 Remove on fuel tank side.
4 Bolt (fuel tank) 2
5 Fuel tank 1
6 Side cover (left) 1
7 Side cover (right) 1
8 Headlight coupler 1
9 Headlight 1
13
4
2
3
SEAT, FUEL TANK AND SIDE COVERS

ENG
4 - 2
EXHAUST PIPE AND SILENCER
EC4S0000
EXHAUST PIPE AND SILENCER
ÅFor USA
ıExcept for USA
Extent of removal:1 Silencer removal2 Exhaust pipe removal
Extent of removal Order Part name Q’ty Remarks
EXHAUST PIPE AND
SILENCER REMOVAL
Preparation for removal Side cover (right) Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Bolt (clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Silencer 1
5 Clamp 1
6 Nut (exhaust pipe) 1
7 Bolt (exhaust pipe) 1
8 Exhaust pipe 1
9 Gasket 2
2
1
2

ENG
4 - 4
RADIATOR
EC450001
RADIATOR
Extent of removal:1 Radiator removal2 Coolant reservoir removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
1 Engine guard (right) 1
2 Panel 2
3 Clamp 8
4 Radiator (right) 1
5 Hose 2 1
6 Hose 3 1
7 Hose 4 1
8 Pipe 2/O-ring 1/1
9 Radiator breather hose 1
10 Radiator (left) 1
1

ENG
4 - 8
CARBURETOR
CARBURETOR
ÅWR426F
ıWR400F
Extent of removal:1 Carburetor removal
Extent of removal Order Part name Q’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Clamp 1
2 Band 1
3 TPS coupler 1
4 Throttle cable cover 1
5 Throttle cable 2
6 Throttle cable cap 1
7 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).
8 Clamp (carburetor joint) 2 Loosen the screws (carburetor joint).
9 Carburetor 1
10 Carburetor joint 1
1

ENG
4 - 22
CAMSHAFTS
CAMSHAFTS
CYLINDER HEAD COVER
Extent of removal:1 Cylinder head cover removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD COVER
REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
1 Spark plug 1
2 Engine upper bracket (right) 1
3 Engine upper bracket (left) 1
4 Cylinder head breather hose 1
5 Oil tank breather hose 1
6 Bolt (cylinder head cover) 2
7 Cylinder head cover 1
8 Gasket 1
9 Timing chain guide (upper) 1
1

ENG
4 - 29
CYLINDER HEAD
CYLINDER HEAD
CYLINDER HEAD
Extent of removal:1 Cylinder head removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator Refer to “RADIATOR” section.
Carburetor Refer to “CARBURETOR” section.
Camshaft Refer to “CAMSHAFTS” section.
1 Decompression cable 1
2 Cable guide 1
3 Bolt 1
4 Decompression shaft 1
5 Oil delivery pipe 1
6 Nut (M6) 2
7 Nut (M8) 2
8 Bolt (L = 150 mm) 2
9 Bolt (L = 160 mm) 2
10 Cylinder head 1
1

ENG
4 - 84
CDI MAGNETO
EC4L0000
CDI MAGNETO
Extent of removal:1 CDI magneto removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Bolt [radiator (left)]
Disconnect the CDI magneto
lead.Refer to “RADIATOR” section.
1 Engine guard (left) 1
2 Shift pedal 1
3 Crankcase cover (left) 1
4 Gasket 1
5 Dowel pin 2
6 Nut (rotor) 1 Use special tool.
Refer to “REMOVAL POINTS”.
7 Rotor 1
8 Stator 1
9Woodruff key
1
1