Yamaha FZR400 Service Manual
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
IMPORTANT INFORMATION.
PREPARATION FOR REMOVAL
ALL REPLACEMENT PARTS
GASKETS, OIL SEALS, AND O-RINGS
LOCK WASHERS/PLATES AND COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
SPECIAL TOOLS.
FOR TUNE UP
FOR ENGINE SERVICE
FOR CHASSIS SERVICE
FOR ELECTRICAL COMPONENTS
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CHAPTER 2.
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE................................................2-
CHASSIS...............................................2-11
ELECTRICAL
GENERAL TORQUE SPECIFICATIONS.
DEFINITION OF UNITS
LUBRICATION POINT AND GRADE OF LUBRICANT
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l-l
l-l
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l-2
l-2
l-4
1-4
l-5
1-B
l-9
2-l
2-4
.2-14
.2-16
2-16
2-17
4
LUBRICATION DIAGRAM. . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
COOLANT DIAGRAM
CABLE ROUTING
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2-20
2-21
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
MAINTENANCE INTERVALS CHART
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM
GENERAL MAINTENANCE/LUBRICATION
COWLING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
ENGINE .....................................................
EXUP CABLE ADJUSTMENT (For California only)
VALVE CLEARANCE ADJUSTMENT
CARBURETOR SYNCHRONIZATION
IDLE SPEED ADJUSTMENT
THROTTLE CABLE FREE PLAY ADJUSTMENT
SPARK PLUG INSPECTION
IGNITION TIMING CHECK
COMPRESSION PRESSURE MEASUREMENT
ENGINE OIL LEVEL INSPECTION
ENGINE OIL REPLACEMENT
ENGINE OIL FILTER REPLACEMENT
CLUTCH ADJUSTMENT.
AIR FILTER CLEANING
CARBURETOR JOINT INSPECTION
FUEL LINE INSPECTION
CRANKCASE VENTILATION HOSE INSPECTION ................
EXHAUST SYSTEM INSPECTION
COOLANT LEVEL INSPECTION
COOLANT REPLACEMENT
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3-1
.3-l
.3-l
.3-4
3-7
3-7
3-8
3-17
3-18
3-19
3-20
3-21
3-23
3-27
3-27
3-27
3-28
3-28
3-29
3-29
CHASSIS
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FRONT BRAKE ADJUSTMENT
REAR BRAKE ADJUSTMENT
BRAKE FLUID INSPECTION
BRAKE PAD INSPECTION
REAR BRAKE LIGHT SWITCH ADJUSTMENT. .................. 3-33
BRAKE HOSE INSPECTION
AIR
BLEEDlNG............................................3-3
DRIVE CHAIN SLACK ADJUSTMENT
DRIVE CHAIN LUBRICATION
STEERING HEAD INSPECTION
FRONT FORK INSPECTION
REAR SHOCK ABSORBER ADJUSTMENT
TIRE INSPECTION
WHEEL INSPECTION
CABLE INSPECTION
LUBRICATION
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................................... 3-33
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3-32
3-32
3-32
4
3-37
3-37
3-40
3-41
3-42
ELECTRICAL.
BATTERY INSPECTION
FUSE INSPECTION
HEADLIGHT BEAM ADJUSTMENT
HEADLIGHT BULB REPLACEMENT
TAIL/BRAKE BULB REPLACEMENT
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CHAPTER 4.
ENGINE OVERHAUL
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3-44
3-44
3-46
3-46
3-47
3-48
ENGINE REMOVAL
LOWER COWLING, CENTER COWLING,
UPPER COWLING AND TOP COVER.
FUEL TANK
ENGINEOIL..
COOLANT.................................................4-
AIR FILTER CASE AND CARBURETOR.,
RADIATOR................................................4-
MUFFLER ASSEMBLY
CLUTCH CABLE AND DRIVE CHAIN
LEADS....................................................4-
ENGINE REMOVAL
ENGINE DISASSEMBLY
CYLINDER HEAD COVER, CAMSHAFT AND
CYLINDER HEAD
CYLINDER AND PISTON
STARTER CLUTCH
CLUTCH..................................................4-13
A.C. MAGNETO
WATER PUMP
OIL PUMP AND SHIFT SHAFT
OIL PAN AND OIL STRAINER.
STARTER MOTOR
CRANKCASE DISASSEMBLY
TRANSMISSION, SHIFTER AND SHIFT CAM.
CRANKSHAFT
VALVE PAD AND VALVE
CONNECTING ROD
INNER ROTOR (OIL PUMP).
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.4-l
.4-l
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1
1
.4-l
2
.4-2
.4-4
4
.4-5
.4-7
.4-7
.4-10
.4-12
.4-14
.4-15
.4-16
.4-17
4-18
4-18
4-19
4-20
4-21
4-23
4-23
INSPECTION AND REPAIR
CYLINDER HEAD
VALVE...................................................4-2
VALVE GUIDE
VALVE SEAT.
VALVE SPRING
VALVE LIFTER
CAMSHAFT, CAM CHAIN AND CAM SPROCKET
CYLINDER AND PISTON
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4-24
4-24
5
.4-26........
.4-27
.4-30
.4-31
.4-31
.4-33
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