Yamaha FZR400 Service Manual Ch1
CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
SPECIFICATIONS ...............................................
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
CHASSIS
TIGHTENING TORQUE
GENERAL TORQUE SPECIFICATIONS ..........................
PERIODIC INSPECTIONS AND ADJUSTMENTS
CHASSIS
DRIVE
CHASSIS
REARWHEEL ...............................................
FRONT AND REAR BRAKE
......................................................
REMOVAL ..............................................
INSPECTION ............................................
INSTALLATION .........................................
STATIC WHEEL BALANCE ADJUSTMENT ...................
BRAKE PAD REPLACEMENT
CALIPER DISASSEMBLY
MASTER CYLINDER DISASSEMBLY ........................
INSPECTION AND REPAIR
ASSEMBLY.. ........................................... 26
................................................
...................................................
CHAIN SLACK ADJUSTME NT ........................
.......................................
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1
1
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2
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3
3
4
5
6
6
6
8
8
9
10
10
11
12
14
19
21
23
MOTORCYCLE IDENTIFICATION
GENERAL
INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number @ is stemped
into the right side of the steering head.
Starting serial number:
FZR400A
JYA3BFEO *
FZR400SAC
I
NOTE:
The vehicle identification number is used to
identify your motorcycle and may be used to
register your motorcycle with the licensing
authority in your state.
JYASFHCO *
(Except for California):
(For California):
LA012101
LA003101
J
FZRIQOOA
ENGINE SERIAL NUMBER
The engine serial number
right side of the
FZR400A
FZR400SAC
I
NOTE:
@The
first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
@Designs and specifications are subject to
change without notice.
FZ
R400SAC
engine.
Starting serial number:
3BF-012101
3FH-003101
@
is stamped into the
(Except for California):
(For California):
1
SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
JSPECII
Model
Model Code Number:
Vehicle Identification Number:
Engine Starting Number:
Basic Weight:
With Oil and Full Fuel Tank
Tire:
Type
Size
Manufacture (Type)
FZR400A/FZR400SAC
3BF5 (FZR400A)
3FH3 (FZR400SAC)
JYA3BFEO -X
JYA3FHCO +X-
3BF-012101 (FZR400A)
3FH-003101 (FZR400SAC)
188 kg (414 lb)
191 kg (421 lb)
Tubeless Tubeless
110/70R17-54H 140/60R
BRIDGESTONE BRIDGESTONE
DUNLOP DUNLOP
LA012101
LA003101
(FZR400A)
(FZR400SAC)
Front Rear
(CYl5)
(K5lOF)
(FZR400A)
(FZR400SAC)
(CY16)
(K510)
1 B-64H
-2-
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
CHASSIS
pqq
Model
Front Suspension:
Front Fork Travel
Front Spring Free Length
< Limit > 408 mm (16.1 in)
Collar Length
Spring Rate:
Stroke
Optional Spring No
Oil Capacity
Oil Level (Fully Compression) 92 mm (3.62 in)
Oil Grade Yamaha Fork Oil
Front Disc Brake:
Type
Disc Outside Diameter x Thickness
Pad Thickness
Pad Thickness
.: ‘.I.
. .,
‘,‘;:.‘;.
. ;.
.;:
Kl
K2
Kl
K2
Inner 5.5 mm (0.22 in)
< Limit
Outer 5.5 mm (0.22 in)
< Limit
*
>*
>*
130 mm (5.12 in)
412 mm (16.2 in)
160 mm (6.3 in)
4.4 N/mm (0.5 kg/mm, 25.2
6.6 N/mm (0.7 kg/mm, 37.5
0.0 - 90 mm (0.0 - 3.54 in)
90 - 130 mm (3.54 - 5.12 in)
440
cm3
Bellow the top of inner fork tube without
fork spring
Dual
282 x 4 mm (11
0.5 mm (0.02 in)
0.5 mm (0.02 in)
FZR400A/FZR400SAC
(15.5 Imp
02,
10WT
.lO
x 0.16 in)
lb/in)
lb/in)
14.9 US oz)
or equivalent
Master Cylinder Inside Diameter
4
Caliper Cylinder Inside Diameter
Brake Fluid Type
15.87 mm (0.62
32.10 mm (1.26 in)
DOT#4or DOT#3
in)
-3-
TIGHTENING TORQUE
MAINTENANCE SPECIFICATIONS
-1
Part to be tightened
Front Axle and Outer Tube
Rear Axle and Nut
Handlebar Crown and Inner Tube
Handlebar Crown and Steering Stem
Brake Caliper (Front/Rear)
Bleed Screw and Brake Caliper
Brake Hose and Union Bolt
Front Master Cylinder and Master Cylinder Holder
Front Master Cylinder and Cylinder Cap
Front Fender and Outer Tube
Handlebar and Inner Tube
Engine Mounting: Front
Rear - Upper
Rear - Lower
Down Tube and Frame: Front
Rear
Footrest Bracket and Frame
Pivot Axle and Nut
Relay Arm and Frame
Arm and
Arm and Relay Arm
Rear Shock Absorber and Relay Arm
Rear Shock Absorber and Frame
Footrest and Footrest Bracket
Rear Footrest Bracket and Frame
Rear Master Cylinder and Rear Arm Bracket
Cowling and Stay
Compression Bar and Brake Caliper Bracket
Front Fork Pinch Bolt
Sprocket and Clutch Hub
Brake Disc and Clutch Hub
Inner Tube and Steering Stem
Frame and Rear Frame: Upper
Swingarm
Lower
Thread size
MI4x
I.5
Ml6 x 1.5
M8 x I.25
M22 x 1.0
MIOx
1.25
M8 x 1.25
MIOx
1.25
M6 x 1.0
M5 x 0.8
M6 x 1.0
M8 x 1.25
MlOx
1.25
MlOx
1.25
M8
x 1.25
MlOx
I.25
M8 x 1.25
Ml0 x 1.25
Ml4x
1.5
MIOx
1.25
Ml0 x 1.25
MlOx
I.25
MIOx
I.25
Ml0 x 1.25
Ml0 x 1.25
M8 x 1.25
M8 x I.25
M6 x 1.0
M8 x I.25
M8 x I.25
M8 x I.25
M8 x 1.25
M8 x I.25
MlOx
1.25
Ml2 x 1.25
-
-r
Tightening torque
Nm
58 5.8
107
26 2.6
110
35 3.5 25
6
26 2.6
9
2
6
23 2.3
55 5.5
55 5.5 40
45 4.5 32
60 6.0
33 3.3 24
33
90 9.0 65
40
40 4.0
40 4.0
40 4.0 29
40 4.0 29
57
20
20 2.0 I4
4
23
20 2.0
32
20 2.0
22
64 6.4 46
88 8.8 64
ma
kg
10.7
11.0 80
0.6 4.3
0.9 6.5
0.2 1.4
0.6 4.3
3.3
4.0 29
5.7
2.0
0.4 2.9
2.3
3.2 23
2.2
ft.
lb
42
77
19
19
17
40
43
24
29
29
41
I4
17
14
14
16
T\
-4-
GENERAL TORQUE SPECIFICATIONS
Is4
P9l
GENERAL
TORQUE
SPECI FICA-
TIONS
This chart specifies torque for standard fasteners
with standard I.S.O. pitch threads. Torque
specifications for special components or assemblies are included in the applicable sections of
this book. To avoid
fastener assemblies in a crisscross fashion, in
progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications
call for clean, dry threads. Components should
be at room temperature.
warpage,
tighten
multi-
A: Distance across flats
6:
Outside thread diameter
DEFINITION OF UNITS
Unit
mm
cm
kg
N
Nm
mskg
Pa Pascal
N/mm Newton per millimeter
L
cm3
r/min
millimeter
centimeter
kilogram
Newton
Newton meter
Meter kilogram
Liter
Cubic centimeter
Revolution per minute
Read
10e3
meter
IO-*
meter
lo3
gram
1 kg x
Nxm
m x kg
N/m2
N/mm
Definition
m/set*
Measure
Length
Length
Weight
Force
Torque
Torque
Pressure
Spring rate
Volume or Capacity
Engine Speed
-5-
DRIVE CHAIN SLACK ADJUSTMENT
PERIODIC INSPECTIONS
AND ADJUSTMENTS
CHASSIS
DRIVE CHAIN SLACK ADJUSTMENT
NOTE:
Before checking and/or adjusting the chain slack,
rotate the rear wheel several revolutions. Check
the chain slack several times to find the point
where the chain is the tightest. Check and/or
adjust the chain slack where the rear wheel is in
this “tight chain” position.
Too little of chain slack will overload the engine
and over vital parts; keep the slack within the
specified limits.
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle on a level place, and
hold it in an upright position.
2. Check:
??
Drive chain slack
@
Out of specification + Adjust.
>
3. Adjust:
??
Drive chain slack
Adjustment steps:
??
Remove the cotter pin @ .
??
Loosen the axle nut @ .
?? Loosen both locknuts
@
(adjuster) and
turn the adjuster @ clockwise or counter-
clockwise until the specified slack is
obtained.
-6-
.
I1NspI(
DRIVE CHAIN SLACK ADJUSTMENT
ADJ m
Clockwise
Counterclockwise
+
Slack is increased.
--,
Slack is decreased.
NOTE:
Turn each adjuster exactly the same amount
to maintain correct axle alignment. (There
are
marks on each side of swingarm; use them to
check for proper alignment.)
??
Tighten the locknut.
??
Tighten the axle nut to specification, while
pushing up or down on the chain to zero
slack.
107 Nm (10.7 m- kg, 77
??
Install the cotter pin.
ft.
lb)
Always use a new cotter pin on the axle nut.
Do not loosen the axle nut after torque
tightening. If the axle nut groove is not
aligned with the cotter pin hole, align groove
rnrith
the hole by tightening up on the axle
nut.
-7-
REAR WHEEL
@Collar
@
Oil seal
@
Bearing
@
Spacer
@
Clutch hub
@Collar
@
Cotter pin
@
Tension bar
CHASSIS
REAR WHEEL
-1
140160R 18-64H
WEAR LIMIT:
1 .O mm (0.04 in)
RIM SIZE:
MT4.00 x 18
RIM
RUNOUT
RADIAL:
2.0 mm (0.08 in)
LATERAL:
LIMIT:
I
-8-
REAR WHEEL
-1
REMOVAL
1. Place the motorcycle on a level place.
Securely support the motorcycle so there is no
danger of it falling over.
2. Elevate the rear wheel by placing a suitable
stand under the swingarm.
3. Remove:
??
Bolts (brake caliper)
@
NOTE:
Do not depress the brake pedal while the caliper
is removed.
4. Loosen:
??
Locknut
??
Adjuster
@
@
5. Remove:
??
Cotter pin
*Axle nut
??
Washer
@I
@I
@
6. Push the rear wheel forward and disconnect
the drive chain @ from the driven sprocket
0
7. Remove:
??
Rear wheel axle
??
Adjuster collars (left and right)
??
Rear wheel
@
8. Remove:
??
Collar (left and right)
-9-
REAR WHEEL
INSPECTION
1. Inspect:
??
Tire
??
Rear wheel axle
??
Wheel
??
Wheel bearings
@Oil seals
Refer to the “FRONT WHEEL - INSPEC-
TION”.
2. Measure:
??
Wheel
runout
Refer to the “FRONT WHEEL - INSPEC- .
TION”.
3. Check:
??
Wheel balance
Refer to the “FRONT WHEEL - INSPEC-
TION”.
INSTALLATION
Reverse the “Removal” procedure.
Note the following points.
1. Lubricate:
??
Rear wheel axle
??
Bearings
*Oil
seals
??
Spacer
??
Collar
Lithium soap base grease
2. Adjust:
??
Drive chain slack
Drive chain slack:
10 - 20 mm (0.4 - 0.8 in)
Refer to the “DRIVE CHAIN SLACK
ADJUSTMENT”.
3. Tighten:
?? Nut (rear wheel axle)
??
Bolts (brake caliper)
REAR WHEEL
??
Do not loosen the axle nut after torque tighten-
lctf=l
&x31
ing.
??
If the axle nut groove is not aligned with the
wheel shaft cotter pin hole, align groove with
the hole by tightening up on the axle nut.
4. Install:
aCotter
??
Always use a new cotter pin on the axle nut.
??
Make sure that the brake hose is routed prop-
pin
erly.
@Brake hose
@
Brake hose guide
STATIC WHEEL BALANCE ADJUSTMENT
NOTE:
?? After replacing the tire and/or rim, wheel
balance should be adjusted.
?? Adjust the wheel balance with brake disc
and wheel hub installed.
1. Adjust:
??
Wheel balance
Refer to the “FRONT WHEEL -STATIC
WHEEL BALANCE ADJUSTMENT”
section.
-ll-
FRONT AND REAR BRAKE
k
@
@
Master cylinder cap
@
Diaphragm
@
Master cylinder kit
@
Master cylinder
@
Brake hose
@
Union bolt
@
Copper washer
@
Joint
1 BRAKE FLUID TYPE:
A DOT#4
If DOT #4 is not available,
I-
1 PAD SPRING
Brake caliper
@I
Pad spring
Q-j?
Piston
@
Piston seal
@
Dust seal
@Brake pad
@
Brake disc
FRONT AND REAR BRAKE
?
The arrow mark @ on the pad spring must pointing
the disc rotating direction.
2 Nm (0.2
rn.
kg, 1.4
ftslb)
pqzq
SYL
135
I
(3.5 m . kg, 25
20 Nm (2.0 ma kg,
ft. lb)
---‘----
1
//
-
,
rd
lJSF
NEW ONE 1
26
\
yr;\r
ONA
@
Reservoir tank cap
@
Bush
@Diaphragm
@
Reservoir tank
@
Reservoir hose
@
Master cylinder
@
Master cylinder kit
@
Brake hose
@
Brake pedal
@
Union bolt
0
Copper washer
@Brake caliper
@Piston
@Piston seal
@
Dust seal
@I
Brake pad
@
Pad shim
@I
Pad spring
@Brake disc
FRONT AND REAR BRAKE
l-s1
@bibi
>/26Nm
(2.6m=kg, 19ft*Ib)I
- 13-
~20NmI2.0m.kn
14ft.lhl)
FRONT AND REAR BRAKE
Disc brake components rarely require disassem-
bly. DO NOT:
??
Disassembly components unless absolutely nec-
essary.
??
Use solvents on internal brake component.
??
Use contaminated brake fluid for cleaning.
Use only clean brake fluid.
??
AIIOW brake fluid to come in contact with the
eyes otherwise eye injury may occur.
??
Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may occur.
?? Disconnect any hydraulic connection other-
wise the entire system must be disassembled,
drained, cleaned, and then properly filled and
bled after reassembly.
pi$q
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
Securely support the motorcycle so there is
no danger of it falling over.
Front brake
1.
Remove:
??
Cover
@
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