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2001 Yamaha Fazer 400 Service Repair Manual

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The Fazer 400, model code 4DX1, is a versatile motorcycle from 2001, designed to excel in sport touring and naked sportbike applications. It combines a sporty, engaging riding experience with...
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2001 Yamaha Fazer 400 Service Repair Manual
The Fazer 400, model code 4DX1, is a versatile motorcycle from 2001, designed to excel in sport touring and naked sportbike applications. It combines a sporty, engaging riding experience with practical comfort for extended journeys and daily commuting. At its heart lies a smooth, liquid-cooled, four-stroke, DOHC inline-four cylinder engine from the Genesis Fazer family, displacing 399 cc and delivering approximately 53 horsepower. This engineering prowess ensures responsive power delivery and reliable performance, making it a capable and enjoyable machine for a wide range of riding scenarios. This comprehensive Factory Service Manual provides detailed guidance for the service and repair of the Fazer 400 (4DX1). It covers essential maintenance procedures, in-depth troubleshooting steps, diagnostics, and technical specifications for all major systems, including the engine, transmission, chassis, brakes, and electrical systems. With its extensive coverage, including component removal, installation, adjustment, and rebuilding, this manual serves as an indispensable resource for owners, mechanics, and technicians seeking to maintain the optimal performance, reliability, and longevity of their Fazer 400.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Fazer 400
Year:
2001
Codes
Model Code:
4DX1
👋 Introduction
Market Position
Segment:
Sport touring, naked sportbike.
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and spirited riding.
Competitive Analysis
Key Competitors Circa 2001:
Honda CB600F Hornet, Suzuki Bandit 600, Kawasaki ER-5, Triumph Speed Four.
Key Features
Design Philosophy:
Combines sporty handling with comfort for longer rides, practical features for everyday use.
Engine Type:
Liquid-cooled, four-stroke, DOHC, inline-four cylinder engine known for its smoothness and power delivery.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Electrical Systems, Engine, Chassis
Page Count
Estimated Pages:
400-500
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel injection system, ignition system, exhaust system.
Transmission:
Clutch operation, gearbox disassembly and reassembly, shift drum and fork inspection, lubrication.
Chassis:
Frame inspection and repair, front fork (telescopic type) disassembly, oil seal replacement, spring rates, rear suspension (monoshock) adjustments and rebuilding, wheel bearings, steering head bearings.
Brakes:
Front and rear brake system inspection, hydraulic fluid replacement, caliper servicing, master cylinder overhaul, brake pad and disc wear specifications, bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting circuits (headlight, taillight, indicators), ignition control module (ICM), sensors (TPS, MAP, etc.), diagnostic codes, troubleshooting common electrical faults.
Fuel System:
Fuel tank removal and cleaning, fuel pump operation, fuel filter replacement, fuel injector cleaning and testing, throttle body inspection.
Procedures Included
Maintenance:
Oil change intervals and procedures, filter replacement, spark plug replacement and gap specifications, air filter cleaning/replacement, chain lubrication and adjustment, brake fluid flush, coolant flush and replacement.
Troubleshooting:
Step-by-step diagnostic flowcharts for common performance issues, starting problems, electrical malfunctions, and braking system faults.
Repair:
Detailed instructions for component removal, installation, adjustment, and rebuilding for all major systems of the motorcycle.
Diagnostics:
Identification of error codes, sensor data interpretation, circuit testing using multimeters and oscilloscopes.
Technical Depth
Depth:
Comprehensive; covers everything from basic rider maintenance to full engine and transmission rebuilds, including detailed torque specifications and component tolerances.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for workshop use.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations for clarity.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Genesis Fazer
Engine Configuration:
Inline 4-cylinder
Displacement:
399 cc
Bore X Stroke:
56.5 mm x 39.2 mm
Valve Mechanism:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Compression Ratio:
11.5:1
Performance
Horsepower Peak:
Approximately 53 hp @ 11,000 rpm (claimed)
Torque Peak:
Approximately 3.7 kg-m @ 9,000 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
19 Liters
Lubrication System
Oil Type Recommendation:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.
Oil Capacity W Filter:
3.4 Liters
Ignition System
Ignition Type:
Transistor Controlled Ignition (TCI)
Spark Plug Type:
NGK CR9E (or equivalent)
Spark Plug Gap:
0.8 - 0.9 mm
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed
Clutch Type:
Wet, multiple disc
Final Drive:
Chain drive
Features
Gear Ratios:
1st: 2.750, 2nd: 2.056, 3rd: 1.650, 4th: 1.350, 5th: 1.150, 6th: 0.965
Transmission Oil Type:
Yamalube 4 (or equivalent) SAE 10W-30 API SE, SF, SG, SH, SJ
Transmission Oil Capacity:
1.1 Liters
📐 Dimensions
Exterior
Length:
2,085 mm
Width:
745 mm
Height:
1,160 mm
Wheelbase:
1,440 mm
Ground Clearance:
140 mm
Weights
Dry Weight:
174 kg
Wet Weight:
Approx. 196 kg (fully fueled, fluids)
Load Capacity:
Typically rated for rider and passenger plus moderate luggage.
Wheels Tires
Front Tire Size:
120/60ZR17 M/C (55W)
Rear Tire Size:
160/60ZR17 M/C (69W)
Front Wheel Type:
Cast aluminum alloy
Rear Wheel Type:
Cast aluminum alloy
Front Wheel Rim Size:
MT3.50 x 17
Rear Wheel Rim Size:
MT5.00 x 17
🛡️ Safety Features
Ratings
Crash Safety Ratings:
Motorcycle safety is typically assessed based on design features and rider skill, not formal crash test ratings like cars. The manual covers safe operating procedures.
Active Features
Braking System:
Hydraulically operated disc brakes, front and rear, for effective stopping power.
Suspension System:
Telescopic front forks and a mono-cross rear suspension system designed for stable handling and feedback.
Passive Features
Lighting:
Halogen headlight, LED taillight and brake light, amber turn signals for visibility.
Ergonomics:
Upright riding position to reduce fatigue on longer journeys.
💡 Technology Features
Infotainment
Display Features:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge.
Driver Assistance
ABS Availability:
ABS (Anti-lock Braking System) was not a standard or widely available option on the 2001 Fazer 400 model. It may have been an aftermarket addition or available on specific regional variants.
Connectivity
Connectivity Features:
N/A - This motorcycle model predates widespread integration of modern connectivity features found in contemporary vehicles.
🔧 Maintenance
Service Intervals
First Service:
1,000 km or 1 month (whichever comes first).
Subsequent Services:
Every 6,000 km or 6 months (whichever comes first). Includes oil filter, spark plugs, valve clearance checks, brake and clutch fluid, throttle cable, etc.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40 recommended for most ambient temperatures.
Brake Fluid Type:
DOT 4 (ISO Class 4)
Coolant Type:
High-quality ethylene glycol-based coolant with de-ionized water (50:50 mix).
Fork Oil Type:
Yamaha Genuine Fork Oil (or equivalent) SAE 10 (or per manual specification).
Fork Oil Level:
125 mm (measured from top of inner tube with spring removed and fork fully compressed).
Known Issues
Common Wear Items:
Brake pads, tires, chain and sprockets, clutch plates, wheel bearings.
Potential Electrical Issues:
Occasional regulator/rectifier failure, wiring harness wear, especially at steering head.
Engine Performance Tips:
Regular cleaning of fuel injectors and throttle bodies, checking air filter, and ensuring correct spark plug gap contributes to optimal performance.
📚 Vehicle History
Brand Heritage
Yamaha Motors Corporation:
Founded in 1955, Yamaha Motor Corporation is a leading manufacturer of motorcycles, marine products, and powersports vehicles, known for its innovation and performance.
Model Evolution
Fazer Lineage:
The Fazer line has a history of providing versatile motorcycles combining sportbike performance with practical touring capabilities. The 400cc variant was primarily for markets with engine displacement restrictions.
Production
Production Period:
The Fazer 400 series, including the 2001 model, was produced for various markets throughout the late 1990s and early 2000s.
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
Generally well-received for its balanced performance, handling, and versatility within its class, often praised for its smooth inline-four engine.
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