Yamaha WR400 WR400F 2000-2008 Service Repair Workshop Manual

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Art.-Nr: 57978

Stichworte: 2000 2001 2002 2003 2004 2005 2006 2007 2008 Marine Motorcycle Sterndrive WR400 WR400F Yamaha

Produktvarianten

Beschreibung

This manual covers the Yamaha WR400F, a versatile off-road motorcycle produced from 2000 through 2008. Known for its robust four-stroke, liquid-cooled, 396cc engine featuring a 5-valve DOHC design, the WR400F delivers a potent blend of motocross power and enduro capability. Its engineering emphasizes reliability and performance, making it a favored choice for enthusiasts and competitors in various off-road disciplines. The model's design incorporates advanced suspension systems, including front forks and a rear shock, along with a powerful braking system and a durable chassis, all contributing to its strong reputation in the off-road community. This comprehensive service repair workshop manual provides detailed guidance for owners, mechanics, and technicians. It encompasses a wide range of essential information, including routine maintenance procedures, periodic checks and adjustments, in-depth troubleshooting guides, and complete repair and rebuild instructions for all major systems. Key areas covered include the engine, fuel system, cooling system, transmission, electrical system, suspension, brakes, and bodywork. With clear text, diagrams, illustrations, and wiring schematics, this manual is designed to facilitate efficient maintenance and repair, ensuring the optimal performance and longevity of your Yamaha WR400F.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

WR400F

Model Variant:

WR400

Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008

Codes

Engine Code Range:

Likely to cover 4BF engine designation (specific code varies by year and market, but the WR400F engine family is consistent)

Chassis Code Range:

Likely to cover 5TJ, 5VK, and related chassis designations (specific code varies by year and market)

👋 Introduction

Market Position

Target Audience:

Yamaha WR400F owners with basic mechanical skills, independent repair professionals, and enthusiasts seeking detailed maintenance and repair knowledge.

Competitive Analysis

Comparison To Dealer Manuals:

Contains the same specifications and procedures used by authorized Yamaha dealer service departments.

Key Features

Content Highlights:

Step-by-step instructions, diagrams, illustrations, wiring schematics, comprehensive specifications.

Value Proposition

Cost Savings:

Enables owners to perform routine maintenance and repairs, saving significant money on labor costs.

Usability

Accessibility:

Viewable on PC, Mac, and many mobile devices; printable pages for garage use.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop, Troubleshooting

Secondary Coverage:

Routine Maintenance, Periodic Checks and Adjustments, Specifications, Wiring Diagrams

Page Count

Estimated Page Count:

While not explicitly stated, professional workshop manuals of this scope typically range from 300 to 800+ pages depending on the depth of detail.

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine specifications, engine removal/installation, top-end overhaul (cylinder, piston, valves), bottom-end overhaul (crankshaft, connecting rod, bearings), timing system, lubrication system.

Fuel System:

Carburetor (Mikuni BDSR40/BDSR39 for most years), fuel pump, fuel lines, fuel tank, fuel filter replacement.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, coolant specifications and capacity.

Transmission Drivetrain:

Transmission internals, gear selection, clutch operation, drive chain maintenance, sprocket replacement, lubrication.

Electrical System:

Ignition system, lighting, charging system (stator, rectifier/regulator), battery, starter motor, wiring harnesses, electrical component testing.

Suspension Steering:

Front forks (KYB USD, including damping and spring adjustments), rear shock absorber (KYB, including spring preload and damping adjustments), steering head bearings, linkage systems.

Brakes:

Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, pad wear inspection, rotor condition.

Bodywork Chassis:

Frame inspection, plastic component removal/installation, seat, fuel tank, fenders, exhaust system.

Procedures Included

Maintenance:

Routine maintenance (oil changes, filter replacements, chain adjustment), periodic checks, lubrication schedules.

Troubleshooting:

Diagnostic procedures for common and advanced issues, symptom-based troubleshooting guides.

Repair Rebuild:

Step-by-step instructions for component disassembly, repair, and reassembly of major systems.

Adjustments:

Carburetor adjustment, suspension tuning, clutch and brake lever adjustments, idle speed settings.

Wiring Diagrams:

Detailed wiring schematics for electrical components and systems.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Printable (individual pages can be printed)

Readability:

Clear and concise text with diagrams and illustrations.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, Liquid-cooled, DOHC, 5-valve, Single-cylinder

Displacement:

396cc

Bore X Stroke:

81.0 mm x 77.0 mm

Compression Ratio:

Approximately 12.0:1 (subject to minor variations by year)

Performance

Horsepower:

Around 45-50 HP (estimated, not explicitly stated in product info)

Torque:

Around 35-40 Nm (estimated, not explicitly stated in product info)

Fuel System

Carburetor Type:

Mikuni BDSR40/BDSR39 (likely, depending on specific year/market)

Fuel Type:

Unleaded gasoline

Lubrication

Oil Type:

Yamalube 4 (or equivalent API SG, SAE 10W-30, 15W-40, or 20W-50 viscosity recommended based on temperature)

Oil Capacity:

Approximately 1.75 Liters (with filter change, subject to variation by year)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet, multi-plate

Optional

Optional Transmission Types:

N/A (standard for this model)

Features

Gear Ratios:

Specific gear ratios will be detailed within the manual.

Transmission Fluid:

Yamaha Gear Oil (or equivalent API GL-4, SAE 80W-90 viscosity recommended)

Transmission Fluid Capacity:

Approximately 0.75 Liters (subject to variation by year)

📐 Dimensions

Exterior

Overall Length:

Approximately 2180 mm (subject to minor variation by year)

Overall Width:

Approximately 825 mm (subject to minor variation by year)

Overall Height:

Approximately 1260 mm (subject to minor variation by year)

Weights

Dry Weight:

Approximately 114 kg (subject to minor variation by year)

Wet Weight:

Approximately 118 kg (with all necessary fluids, estimated)

Fuel Capacity:

Approximately 9.0 Liters (including reserve, subject to minor variation by year)

🛡️ Safety Features

Ratings

Safety Ratings:

As a dirt bike, formal crash safety ratings like those for cars are not applicable. However, the manual covers safe operating procedures and maintenance for optimal performance and reliability.

Active Features

Active Safety Features:

Powerful braking system, responsive suspension, ergonomic design for rider control.

Passive Features

Passive Safety Features:

Durable chassis construction, protective bodywork.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure off-road motorcycle, no infotainment features).

Driver Assistance

Driver Assistance Systems:

N/A (Pure off-road motorcycle, no electronic driver assistance features).

Connectivity

Connectivity Features:

N/A (Pure off-road motorcycle, no connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km or 6 months, whichever comes first (recommendation from typical manual guidance).

Oil Filter Replacement:

Every 2000 km or 12 months (recommendation from typical manual guidance).

Air Filter Cleaning:

Frequent cleaning recommended based on operating conditions (e.g., every few rides in dusty conditions).

Spark Plug Inspection:

Every 1000 km or 6 months (recommendation from typical manual guidance).

Drive Chain Lubrication Adjustment:

Every 500 km or after riding in wet/muddy conditions.

Fluid Specifications

Coolant Type:

Yamaha Coolant (or equivalent mixture of ethylene glycol and distilled water, typically 50/50 mix).

Brake Fluid Type:

DOT 4 brake fluid.

Known Issues

Common Wear Items:

Clutch plates, brake pads, fork seals, valve stem seals, drive chain and sprockets.

Potential Durability Concerns:

Overheating if cooling system is not maintained, carburetor jetting may require adjustment for altitude/temperature changes.

📚 Vehicle History

Brand Heritage

Yamaha Heritage:

Yamaha Motor Corporation has a rich history in motorsports and performance motorcycles, dating back to the mid-20th century, known for innovation and reliability.

Model Evolution

Wr400F Evolution:

The WR400F was a significant model in Yamaha's off-road lineup, evolving from earlier YZ-based enduro machines, offering a blend of motocross power and trail capability. It was succeeded by the WR426F and later the WR450F, representing continuous development in engine performance and chassis dynamics.

Production

Production Period:

Produced from 1998 through the 2000-2008 model years (as indicated by the manual's coverage).

🏆 Awards & Recognition

Recognitions

Motorsport Success:

While specific awards for the WR400F model itself may not be widely documented, Yamaha's WR line has a strong history of success in various off-road racing disciplines like enduro and GNCC.

Ratings

Performance Reviews:

Reviews from the era often praised its powerful engine, capable suspension, and all-around off-road performance, positioning it as a competitive machine for its time.