Target Audience:
Mechanical technicians familiar with BRP products and general automobile practices, as well as Yamaha FZR400 owners seeking to perform their own maintenance and repairs.
Manual Advantage:
Provides detailed information previously available only in authorized dealer service departments, enabling professional-quality service and cost savings for owners.
Emphasis On Safety:
Highlights crucial safety information through WARNING, CAUTION, and NOTE symbols, promoting safe working practices.
Inclusion Of Proprietary Components:
Incorporates instructions for proprietary components from their respective manufacturers for a holistic understanding of system performance.
Applicable Years:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994
Manual Type:
Workshop Repair Service Manual
Format:
PDF (Digital Download)
Engine:
Complete engine overhaul, disassembly, assembly, tuning, lubrication system, cooling system, fuel system, exhaust system.
Transmission:
Gearbox disassembly, assembly, inspection, lubrication.
Electrical System:
Ignition system, charging system, lighting, wiring diagrams, troubleshooting electrical faults.
Fuel System:
Carburetor removal, installation, adjustment, overhaul, fuel tank, fuel pump, fuel lines.
Bodywork:
Fairing removal and installation, body panel repairs, seat, handlebars, controls.
Suspension:
Front fork service, rear shock absorber inspection and maintenance.
Brakes:
Front and rear brake system maintenance, caliper overhaul, brake fluid replacement.
Maintenance:
Routine servicing, oil changes, filter replacements, spark plug checks, chain adjustment, general inspections.
Repair:
Detailed step-by-step repair instructions for all major components.
Troubleshooting:
Diagnostic procedures for common problems, fault finding charts.
Disassembly Assembly:
Comprehensive instructions for dismantling and reassembling all parts of the motorcycle.
Technical Depth:
Covers basic maintenance to complete engine and transmission rebuilds, suitable for professional technicians and experienced DIY enthusiasts.
Engine Type:
Inline-four cylinder, 4-stroke, DOHC, liquid-cooled
Horsepower:
Approx. 53-60 PS (39-44 kW) at 11,000-12,500 rpm (varies by year and market)
Torque:
Approx. 36-40 Nm (26.5-29.5 lb-ft) at 10,000-11,000 rpm (varies by year and market)
Carburetion:
Mikuni CV carburetors (e.g., VM26SS or BDST36)
Cooling Method:
Liquid-cooled
Oil Type Recommendation:
Yamaha's recommended motorcycle oil, e.g., SAE 20W-40 or 10W-40 (specific viscosity depends on ambient temperature, refer to manual for precise specifications).
Ignition System:
Digital CDI with electronic advance
Length:
Approx. 2,040-2,060 mm (80.3-81.1 in) - varies by year.
Width:
Approx. 710-730 mm (28.0-28.7 in) - varies by year.
Height:
Approx. 1,135-1,155 mm (44.7-45.5 in) - varies by year.
Dry Weight:
Approx. 150-155 kg (331-342 lbs) - varies by year.
Wet Weight:
Approx. 170-175 kg (375-386 lbs) - varies by year.
Fuel Tank Capacity:
Approx. 16 liters (4.2 US gal)
Coolant Capacity:
Approx. 1.2 liters
Crash Test Ratings:
N/A (Motorcycle)
Braking System:
Dual front disc brakes, single rear disc brake (caliper types may vary).
Suspension Features:
Telescopic front forks, Monocross rear suspension for improved stability and handling.
Lighting:
Halogen headlamp, tail light, turn signals.
Instrumentation:
Analog tachometer, speedometer, fuel gauge, temperature gauge, odometer, trip meter, indicator lights.
ABS:
Anti-lock Braking System (ABS) was not a standard or common option on this model range.
Electronic Features:
Digital CDI ignition, liquid cooling, electric starter. No modern electronic rider aids or connectivity.
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first. Specific recommendations in the manual.
Spark Plug Replacement:
Typically every 10,000-15,000 km (6,000-9,000 miles), but inspection recommended at earlier intervals.
Chain Maintenance:
Clean and lubricate every 500-1,000 km (300-600 miles). Adjust slack as needed.
Engine Oil Viscosity:
SAE 20W-40 or 10W-40 (refer to manual for seasonal recommendations).
Coolant Type:
Permanent type coolant (ethylene glycol based) mixed with distilled water in a 50:50 ratio.
Brake Fluid Type:
DOT 3 or DOT 4.
Carburetor Cleaning:
Carburetors can become gummed up with age and fuel instability, requiring periodic cleaning and synchronization.
Cam Chain Tensioner:
Some models may develop a noisy cam chain tensioner over time, requiring replacement.
Suspension Seals:
Front fork seals can degrade with age and mileage, leading to oil leaks.
Yamaha Motorcycles:
Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Renowned for innovation and performance across various motorsport disciplines.
Fzr400 Development:
The FZR400 was part of Yamaha's FZR series, known for its sporty performance and advanced technology for its era. It often served as a middleweight sportbike, bridging the gap between smaller displacement models and larger supersports.
Manufacturing Location:
Japan
