Positioning:
Performance-oriented sportbike in the 400cc class, aimed at riders seeking agility and responsive handling.
Target Audience:
Enthusiast riders, DIY mechanics, aspiring motorcycle technicians.
Competitors:
Honda CBR400RR, Suzuki GSX-R400, Kawasaki ZXR400 (in markets where these were prevalent).
Features:
Compact 400cc four-cylinder engine, advanced chassis design for its era, sporty ergonomics, capable of spirited riding.
Benefits:
Empowers owners to perform maintenance and repairs, saving significant costs compared to dealership services. Provides in-depth technical understanding.
Manual Value:
Essential tool for maintaining the longevity and performance of the FZR400, crucial for preserving its value.
Year Coverage:
1986, 1987, 1988, 1989, 1990
Geographic Coverage:
Global (assumed, as service manuals typically aim for broad applicability, though regional variations may exist).
Estimated Page Count:
Comprehensive (typically 300-600+ pages for a full shop manual).
Type:
Shop Manual / Service Manual / Repair Manual
Language:
English (implied by product description context, standard for technical manuals).
Format:
Digital Download (PDF, compatible with PC, MAC, Tablets & Smartphones)
Engine:
Complete engine disassembly, assembly, inspection, tuning, and component diagnosis (cylinder head, pistons, crankshaft, valve train, lubrication system, cooling system).
Fuel System:
Carburetor overhaul and adjustment (likely Mikuni CV units), fuel tank, fuel pump, fuel lines, fuel filter.
Ignition System:
CDI, ignition coils, spark plugs, timing checks, troubleshooting.
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation, gear selection mechanism.
Chassis Frame:
Frame inspection, steering head bearing service, general chassis components.
Suspension:
Front fork (telescopic) disassembly, seal replacement, oil specification, rear shock absorber (monoshock) overhaul and adjustment.
Brakes:
Front and rear disc brake systems, caliper overhaul, brake pad replacement, master cylinder service, brake fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, battery, charging system (alternator, rectifier/regulator), starter motor, fuses, relays, instrumentation, switches.
Cooling System:
Radiator, cooling fan, thermostat, water pump, coolant specifications, flushing procedures.
Exhaust System:
Exhaust pipe and silencer inspection, potential for emissions control system details.
Bodywork Fittings:
Fairing removal and installation, seat, fuel tank mounting, minor body panel adjustments.
Maintenance:
Routine checks, lubrication points, filter changes, spark plug replacement, chain adjustment, brake fluid changes, coolant changes.
Troubleshooting:
Systematic diagnosis of common problems, fault finding charts, electrical symptom diagnosis.
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Technical Specifications:
Torque values for critical fasteners, clearances, tolerances, fluid capacities, electrical specifications.
Component Inspection:
Guidance on checking wear and tear on engine internals, transmission parts, suspension components, and brake system parts.
Depth:
Comprehensive (from basic user maintenance to complete engine rebuilds and complex electrical diagnostics).
Diagnostic Capabilities:
Advanced diagnostic procedures, including electrical troubleshooting with multimeter usage and interpretation of symptoms.
Rebuild Procedures:
Detailed instructions for rebuilding major components like the engine, transmission, and carburetors.
Type:
4-stroke, DOHC, inline-four cylinder
Displacement:
399 cc (approximate, actual may vary slightly by sub-model)
Bore X Stroke:
Typically around 57.0 mm x 39.2 mm
Compression Ratio:
Around 11.5:1 to 12.0:1
Horsepower:
Approximately 53-60 PS (39-44 kW) at 11,000-12,000 RPM (market dependent, often restricted in some regions).
Torque:
Approximately 37-40 Nm (27-30 lb-ft) at 10,000-11,000 RPM.
Carburetion:
4 x Mikuni constant velocity (CV) carburetors (e.g., VM29 or similar).
Fuel Type:
Unleaded gasoline (RON 91 or higher recommended).
Safety Certification:
Compliant with relevant safety standards of its era (e.g., ADR for Australia, DOT for US, etc. - specific details depend on market).
Braking System:
Dual front disc brakes, single rear disc brake. ABS was not common in this class at this time.
Handling:
Designed for agile handling, featuring a balanced chassis and suspension setup.
Lighting:
Halogen headlight, tail light, turn signals.
Oil Change:
Every 3,000 - 5,000 km or 6 months, whichever comes first.
Spark Plugs:
Inspect every 5,000 km, replace as needed (typically every 10,000-15,000 km).
Chain Lubrication Adjustment:
Lubricate every 500 km, adjust tension as needed to maintain 20-30mm free play.
Valve Clearance Check:
Every 10,000 - 15,000 km (critical for engine health).
Engine Oil:
Yamaha recommends Yamalube 4 (or equivalent) 10W-40 API SE or SF. Check manual for precise SAE viscosity based on ambient temperature.
Coolant:
50% Ethylene Glycol based coolant and 50% distilled water. Use a high-quality motorcycle-specific coolant.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Fork Oil:
Yamaha Suspension Fluid (or equivalent) SAE 10W (capacity per leg typically 460-480cc - verify in manual).
Common Problems:
Carburetor synchronization drift, aging rubber fuel lines, potential wear in the valve train at higher mileage, suspension seal leaks.
Electrical Issues:
Corroded connectors, faulty rectifier/regulator units, worn starter motor brushes can be common with age.
Engine Wear:
Cam chain tensioner wear, potential for carbon buildup in combustion chambers affecting performance.
