2002 YAMAHA WR 400F engine

4 - 82
ENGKICK AXLE AND SHIFT SHAFT
4. Install:
Bolt (shift guide) 1
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
EC4C5301
Shift shaft
1. Install:
Roller 1
Collar 2
Torsion spring 3
Shift shaft 4
NOTE:
Apply the engine oil on the roller and shift
shaft.
Kick axle assembly
1. Install:
Kick gear 1
Plain washer 2
Circlip 3
Ratchet wheel 4
Spring 5
Plain washer 6
Circlip 7
To kick axle 8.
NOTE:
Apply the molybdenum disulfide oil on the
inner circumferences of the kick gear and
ratchet wheel.
Align the punch mark a on the ratchet wheel
with the punch mark b on the kick axle.
New
New
2. Install:
Torsion spring 1
To kick axle 2.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick axle.

4 - 83
ENGKICK AXLE AND SHIFT SHAFT
3. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
Kick axle assembly 1
Plain washer 2
NOTE:
Apply the molybdenum disulfide grease on
the contacting surfaces of the kick axle stop-
per a and stopper plate 3.
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case and make sure the kick axle stopper fits
into the stopper plate.
5. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
Kick idle gear 1
Plain washer 2
Circlip 3
NOTE:
Install the kick idle gear with its depressed
side a toward you.
Apply the engine oil on the kick idle gear
inner circumference.
New

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

4 - 87
ENG

CDI MAGNETO
4. Connect:

CDI magneto lead
Refer to “CABLE ROUTING DIA-
GRAM” section in the CHAPTER 2.
5. Install:

Gasket [crankcase cover (left)]

Crankcase cover (left)
1


Hose holder (cylinder head breather
hose)
2

Bolt [crankcase cover (left)]
NOTE:

Tighten the bolts in stage, using a crisscross
pattern.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

6. Install:

Shift pedal
1


Bolt (shift pedal)
NOTE:

When installing the shift pedal onto the shift
shaft, be sure that the center of the shift pedal
is about 2 mm
a
above the top of the footrest.
7. Install:

Engine guard (left)
1


Hose holder (cylinder head breather
hose)
2

Bolt [engine guard (left)]
1
2
T R..23 Nm (2.3 m · kg, 17 ft · lb)

ENG
4 - 88
ENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is nodanger of it falling over.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable Disconnect at engine side.
Decompression cable and guide Disconnect at engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “CDI MAGNETO” section.
Cylinder head breather hose and
oil tank breather hoseRefer to “CAMSHAFTS” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Spark plug cap
Disconnect the CDI magneto lead.

ENG
4 - 89
ENGINE REMOVAL
Extent of removal:1 Engine removal
Extent of removal Order Part name Q’ty Remarks
1 Engine skidplate 1
2 Neutral switch 1
3 Oil hose 2
4 Chain cover 1
Refer to “REMOVAL POINTS”. 5 Nut (drive sprocket) 1
6 Lock washer 1
7 Drive sprocket 1
8 Clip 1
9 Bolt (brake pedal) 1
10 Brake pedal 1
11 Engine upper bracket (right) 1
12 Engine upper bracket (left) 1
13 Engine lower bracket 2
14 Engine mounting bolt 3
15 Pivot shaft 1
Refer to “REMOVAL POINTS”.
16 Engine 1
1

4 - 90
ENGENGINE REMOVAL
EC4M3000
REMOVAL POINTS
EC4F3100
Drive sprocket
1. Remove:
Nut (drive sprocket) 1
Lock washer 2
NOTE:
Straighten the lock washer tab.
Loosen the nut while applying the rear brake.
2. Remove:
Drive sprocket 1
Drive chain 2
NOTE:
Remove the drive sprocket together with the
drive chain.
EC4M3301
Engine removal
1. Remove:
Pivot shaft 1
NOTE:
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:
Engine 1
From right side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.

4 - 91
ENGENGINE REMOVAL
EC4M5000
ASSEMBLY AND INSTALLATION
EC4M5160
Engine installation
1. Install:
Engine 1
Install the engine from right side.
Pivot shaft 2
Engine mounting bolt (lower) 3
Engine lower bracket 4
Bolt (engine bracket) 5
Engine mounting bolt (front) 6
Engine upper bracket (right) 7
Engine upper bracket (left) 8
Bolt (engine bracket) 9
Engine mounting bolt (upper) 0
EC4M5211
Brake pedal
1. Install:
Spring
Brake pedal 1
O-ring 2
Bolt (brake pedal) 3
Clip 4
NOTE:
Apply the lithium soap base grease on the
bolt, O-rings and brake pedal bracket.
Install the clip with its stopper portion a fac-
ing inward.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
T R..69 Nm (6.9 m · kg, 50 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..69 Nm (6.9 m · kg, 50 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
Drive sprocket
1. Install:
Drive sprocket 1
Drive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.