Class:
Middleweight Supersport Motorcycle
Target Audience:
Enthusiasts seeking a balance of performance and sport-touring capability, riders looking for a capable track day machine in its era.
Competitors 1980S:
Honda CBR400F/VFR400R, Suzuki GSX-R400, Kawasaki ZXR400 (later models), Yamaha's own FZR600.
Engine Type:
Inline-four, DOHC, liquid-cooled.
Frame Type:
Deltabox frame (prominent Yamaha technology).
Aerodynamics:
Full fairing for improved aerodynamics.
Braking System:
Dual front disc brakes, single rear disc brake.
Model Years Covered:
1986, 1987, 1988, 1989, 1990
Engine Variants Covered:
All engine types and configurations for the specified model years.
Trim Levels Covered:
All trim levels.
Transmission Types Covered:
All transmission types.
Estimated Page Count:
Likely 300-600 pages (typical for comprehensive workshop manuals).
Type:
Complete Workshop Service Repair Manual
Download Format:
Digital Download (PDF)
Engine Mechanical:
Engine overhaul, top-end rebuild, bottom-end assembly, piston and ring replacement, valve train maintenance, cylinder head service, crankshaft and connecting rod service, oil pump operation and repair.
Fuel System:
Carburetor overhaul, adjustment, and synchronization; fuel pump testing and replacement; fuel filter service; fuel tank inspection and cleaning.
Ignition System:
Ignition coil testing, spark plug specifications and replacement, CDI unit diagnostics, stator and rotor inspection.
Cooling System:
Radiator service and repair, coolant flush and replacement, thermostat operation, water pump inspection and rebuild, fan operation.
Exhaust System:
Exhaust pipe inspection and replacement, muffler service.
Transmission:
Gearbox inspection, gear selection mechanism repair, clutch inspection and replacement, chain and sprockets service.
Electrical System:
Wiring diagrams, battery maintenance and testing, starter motor operation, charging system analysis (alternator/stator), lighting system troubleshooting, accessory wiring.
Brakes:
Brake fluid replacement, caliper service, brake pad and disc inspection/replacement, master cylinder overhaul, brake hose inspection.
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement, swingarm maintenance.
Steering:
Steering head bearing adjustment and replacement, handlebar service.
Chassis And Bodywork:
Frame inspection, fairing repair and replacement, seat service, fuel tank removal and installation, general body panel maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks, tire pressure checks, general inspection points.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Repair Procedures:
Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Engine Rebuild:
Complete engine disassembly, cleaning, measurement of critical tolerances, part replacement, and reassembly with torque specifications.
Electrical Diagnostics:
Schematic interpretation, voltage and resistance testing of circuits and components.
Suspension Overhaul:
Front fork seal replacement, damping rod service, rear shock linkage lubrication and inspection.
Carburetor Tuning:
Synchronization, idle speed adjustment, jetting recommendations (though specific jetting may vary by region).
Depth:
Comprehensive (A-Z coverage), suitable for home mechanics to professional technicians.
Type:
398cc, 4-stroke, DOHC, liquid-cooled, inline-four cylinder.
Bore X Stroke:
56.0 x 40.5 mm (typical for this displacement).
Compression Ratio:
11.5:1 (typical).
Horsepower:
Approx. 53-59 HP at the crankshaft (depending on market and tuning, often restricted in some markets).
Torque:
Approx. 37-40 Nm (depending on market).
Carburetion:
Four Mikuni CV carburetors (e.g., Mikuni BDSR32).
Fuel Capacity:
Approx. 15-16 Liters.
Oil Change:
Every 3,000-5,000 km or annually.
Air Filter:
Inspect every 5,000 km, clean/replace as needed.
Spark Plugs:
Replace every 10,000-15,000 km.
Chain Adjustment:
Check and adjust every 1,000-2,000 km or as needed.
Engine Oil:
Yamalube 10W-40 or equivalent motorcycle-specific oil meeting API SG or higher.
Engine Oil Capacity:
Approx. 3.2 Liters (without filter change), 3.4 Liters (with filter change).
Coolant:
50/50 mixture of ethylene glycol-based coolant and distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Carburetor Sync:
Carburetors can drift out of sync over time, leading to rough idling and poor throttle response. Regular synchronization is key.
Cam Chain Tensioner:
Automatic cam chain tensioner can weaken, leading to rattling noises. Manual conversion is sometimes performed.
Electrical Connections:
As with many bikes of this era, corrosion can affect electrical connectors, leading to intermittent faults.
Fork Seals:
Front fork seals can degrade over time, causing oil leaks.
Legacy:
Yamaha has a long and successful history in motorcycle racing and performance road bikes, particularly with the FZR series and its revolutionary Deltabox frame.
Development:
The FZR400 was part of Yamaha's FZR lineage, which aimed to bring race-inspired technology to the street. It was positioned as a high-performance, technologically advanced middleweight.
Variants:
Various sub-models and regional variations existed, often with minor cosmetic or tuning differences. The 'Fazer' designation typically implied a sport-touring bias, though the FZR400 was primarily a sportbike.
Production Years:
Mid-1980s to early 1990s (specific to FZR400 model generation).
