Applicable Years:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994
Chassis Codes:
3TJ (may vary by region, e.g., 1WG, 2TK for earlier models)
Engine Codes:
3EN (typically 360cc variant), 3TJ (typically 399cc variant)
Positioning:
The Yamaha FZR400 was a popular sportbike in its era, known for its performance and styling. This manual provides the necessary technical documentation for owners and technicians to maintain and repair these classic motorcycles.
Competition:
Competed with other 400cc class sportbikes of the era from manufacturers like Honda (CBR400), Kawasaki (GPX400), and Suzuki (GSX-R400).
Features:
Contains step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications, mirroring factory dealer documentation.
Engine:
Complete engine overhaul, disassembly, assembly, tuning, troubleshooting, internal components (pistons, rings, valves, crankshaft, camshafts).
Fuel System:
Carburetor operation, adjustment, cleaning, rebuilding; fuel pump, fuel lines, fuel tank maintenance.
Cooling System:
Radiator, cooling fan, water pump, coolant flow, thermostats, hoses, troubleshooting leaks.
Transmission:
Gearbox disassembly, inspection, assembly, gear ratios, shift mechanism, troubleshooting.
Drive Train:
Drive chain maintenance, adjustment, replacement; sprocket inspection and replacement.
Electrical System:
Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, battery), lighting, instruments, troubleshooting electrical faults.
Suspension:
Front fork (fork oil change, seal replacement, spring inspection), rear shock absorber servicing and adjustment.
Brakes:
Front and rear brake caliper maintenance, master cylinder overhaul, brake pad replacement, brake fluid bleeding, troubleshooting.
Steering System:
Handlebar, steering head bearings inspection, adjustment, and replacement.
Frame And Bodywork:
Chassis inspection, body panel removal and installation, seat, fairing components.
Intake And Exhaust:
Airbox, intake boots, exhaust system inspection and maintenance.
Maintenance:
Routine maintenance, periodic checks, adjustments (e.g., valve clearance, carburetor synchronization).
Troubleshooting:
Systematic diagnostic procedures for common and advanced problems.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostics:
Identification of faulty components and operational issues.
Depth:
Comprehensive, covering everything from basic oil changes to full engine rebuilds and electrical system diagnosis.
Target Audience:
Independent mechanics, experienced DIY enthusiasts, and owners seeking detailed knowledge.
Type:
4-stroke, Liquid-cooled, Inline-four cylinder, DOHC, 16-valve
Displacement Cc:
399cc (common variant, some markets may have 360cc or other variations)
Bore X Stroke Mm:
Typically 56.5 mm x 39.0 mm (for 399cc)
Compression Ratio:
Typically 11.5:1 (for 399cc)
Horsepower Ps Rpm:
Around 53-59 PS at 12,000 RPM (varies by market and specific model year)
Torque Nm Rpm:
Around 38 Nm at 10,000 RPM (varies by market and specific model year)
Carburetion:
Typically 4 x Mikuni CV (Constant Velocity) carburetors (e.g., Mikuni BSW26 or similar)
Fuel Delivery:
Gravity feed from fuel tank via petcock, possibly with electric pump on some variants.
Oil Capacity Liters:
Approx. 2.4 - 2.6 Liters (check manual for exact specification)
System:
CDI (Capacitor Discharge Ignition)
Oil Change:
Every 3,000-5,000 km or annually (refer to manual for exact interval and oil type).
Air Filter Cleaning:
Every 3,000-6,000 km or as needed based on riding conditions.
Spark Plug Replacement:
Every 10,000-15,000 km (refer to manual for correct plug type and gap).
Valve Clearance Check:
Every 10,000-12,000 km (crucial for engine performance and longevity).
Engine Oil Type:
Yamaha recommends API SG or higher, JASO MA, viscosity 10W-40 or 20W-50 depending on climate (refer to manual for exact specification).
Coolant Type:
Permanent type ethylene glycol based coolant, mixed with distilled water at a 50:50 ratio.
Fork Oil Grade:
Yamalube Fork Oil 10W or equivalent.
Common Problems:
Potential for carburetor issues (clogging, synchronization), stator/regulator/rectifier failure, aging rubber components (hoses, seals), fork seal leaks.
