2002 YAMAHA WR 400F lights

1 - 1
GEN
INFO

DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1
Clutch lever
2
Decompression lever
3
“ENGINE STOP” button
4
Trip meter
5
Lights switch
6
Front brake lever
7
Throttle grip
8
Radiator cap
9
Fuel tank cap
0
Oil filler plug/dipstick
A
Tail light
B
Kick starter
C
Fuel tank
D
Headlight
E
Radiator
F
Coolant drain bolt
G
Rear brake pedal
H
Valve joint
I
Fuel cock
J
Cold starter knob
K
Hot starter knob (red)
L
Air cleaner
M
Drive chain
N
Shift pedal
O
Front fork
NOTE:


The machine you have purchased may differ
slightly from those shown in the following.

Designs and specifications are subject to
change without notice.
1

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GEN
INFO
CONTROL FUNCTIONS
EC15F000
VALVE JOINT
This valve joint 1 prevents fuel from flowing
out and is installed to the fuel tank breather
hose.
CAUTION:
In this installation, make sure the arrow
faces the fuel tank and also downward.
LIGHTS SWITCH
The lights switch 1 is located on the handle-
bar.
FLAP
In order to prevent water from entering the car-
buretor while the machine is operated in the
rain, attach the accessory flap 1 to the frame
at the rear of the fuel tank.
NOTE:
Riding with the flap attached when it is not
raining can help keep out dust, dirt and sand.

2 - 15
SPECMAINTENANCE SPECIFICATIONS (WR426F)
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench, then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M48 × 1.0 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and protector M6 × 1.0 6 10 1.0 7.2
Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9
Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2
Front fork and hose cover M8 × 1.25 1 16 1.6 11
Front fork and hose cover M6 × 1.0 1 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting M6 × 1.0 1 2 0.2 1.4
Decompression lever holder M5 × 0.8 2 4 0.4 2.9
Lights switch M4 × 0.7 2 2 0.2 1.4
Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Hose guide (front brake hose) M5 × 0.8 2 4 0.4 2.9
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Brake caliper (front and rear) and pad pin plug M10 × 1.0 1 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 1 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 1 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2
Rear brake reservoir tank and frame M6 × 1.0 1 10 1.0 7.2
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench, then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M48 × 1.0 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and protector M6 × 1.0 6 10 1.0 7.2
Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9
Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2
Front fork and hose cover M8 × 1.25 1 16 1.6 11
Front fork and hose cover M6 × 1.0 1 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting M6 × 1.0 1 2 0.2 1.4
Decompression lever holder and protector M5 × 0.8 2 4 0.4 2.9
Lights switch M4 × 0.7 2 2 0.2 1.4
Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Hose guide (front brake hose) M5 × 0.8 2 4 0.4 2.9
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Brake caliper (front and rear) and pad pin plug M10 × 1.0 1 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 1 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 1 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2
Rear brake reservoir tank and frame M6 × 1.0 1 10 1.0 7.2
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22

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SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Hose guide
2Brake hose
3Regulator
4Fuel tank breather hose
5Oil tank breather hose
6Clamp
7Sub wire harness
8Tail light lead
9TPS (throttle position sensor) lead
0Neutral switch lead
AOil hose
BCylinder head breather hose
CHose holder
DCDI magneto lead
EClutch cable
FDecompression cable
GLights switch lead
HCarburetor breather hose
IOverflow hose
JCoolant reservoir tank breather hoseÅPass the fuel tank breather
hose behind handlebar, then
insert it into the steering shaft
hole.
ıPass the decompression
cable, regulator lead and lights
switch lead under where the oil
hose is attached.
ÇFasten the CDI magneto lead,
neutral switch lead and lights
switch lead to the frame with a
plastic locking tie.
ÎFasten the sub wire harness
and lights switch lead to the
frame in front of the protector
of the sub wire harness with a
plastic locking tie and cut off
the tie end.‰Pass the cylinder head
breather hose along the right
side of the oil tank breather
hose.
ÏFasten the sub wire harness
to the frame with a plastic
locking tie ends at the lower
left of the frame and cut off
the tie end. For fastening,
pass the plastic locking tie
through the upper holes in the
engine brackets.
ÌPass the sub wire harness
between the engine brackets.
ÓFasten the TPS lead (in the
sub wire harness) under the
frame so that it does not con-
tact the carburetor.

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SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Lights switch
3Lights switch lead
4Clamp
5Decompression cable
6Clutch cable
7Hose guide
8Trip meter
9Brake hose
0“ENGINE STOP” button leadÅFasten the “ENGINE STOP” button lead to the handlebar with the
plastic band.
ıPass the throttle cables between the handle crown and trip meter.
ÇPass the lights switch leads in front of the “ENGINE STOP” button
lead, then pass the head light lead (of the lights switch leads) in
front of the head pipe.
ÎInstall the trip meter cable so that its bent portion faces the chassis
rear.
‰Install the brake hose so that it contacts the master cylinder projec-
tion and that its bent portion faces downward.

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CHAS
EC5B0000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Headlight
1 Decompression cable 1 Disconnect at the lever side.
2 Decompression lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1
5“ENGINE STOP” button 1
6 Lights switch 1
7 Master cylinder 1 Refer to “REMOVAL POINTS”.
8 Throttle cable cap 1
9 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
10 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
11 Grip (right) 1 Refer to “REMOVAL POINTS”.
12 Tube guide 1
13 Cover (grip cap) 1
14 Collar 1
15 Grip (left) 1 Refer to “REMOVAL POINTS”.
16 Handlebar holder (upper) 2
17 Handlebar 1
1
HANDLEBAR

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CHASHANDLEBAR
8. Install:
Master cylinder 1
Master cylinder bracket 2
Bolt (master cylinder bracket) 3
NOTE:
Install the bracket so that the arrow mark a
faces upward.
First tighten the bolt on the upper side of the
master cylinder bracket, and then tighten the
bolt on the lower side.
9. Install:
Lights switch 1
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
10. Install:
“ENGINE STOP” button 1
Clutch lever holder 2
Bolt (clutch lever holder) 3
Decompressor lever holder 4
Bolt (decompressor lever holder) 5
Clamp 6
NOTE:
The “ENGINE STOP” button, clutch lever
holder, decompression lever holder and
clamp should be installed according to the
dimensions shown.
Pass the “ENGINE STOP” button lead in the
middle of the clutch holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
11. Install:
Clutch cable 1
Decompression cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and decompression cable
end.
B
2
1