Yamaha FZR400 Service Manual Ch567
RADIATOR
@
Radiator assembly
@
Fan motor assembly
@
Radiator cap assembly
@
Radiator cap
0
Radiator cover
RADIATOR
COOLING SYSTEM
@
Hose (Radiator - Outlet)
@Outlet pipe
@O-ring
@Hose (Radiator - Inlet)
COOL #
\
) RADIATOR CAP OPENING PRESSURE:
A
74-103kPa
(0.75 - 1.05
COOLANT CAPACITY:
B
19 L (1.7 Imp qt, 2.0 US qt)
lncludinq all routes
10
Nrn (1.0
‘i
\
kg/cm’,
m-kg,
10.7 - 14.9 psi)
7.2
ftelh)
-1
4
I-Q
1~ 10Nm (l.Om.kg, 7.2ft.Ib)
h
\
‘\
\
P
I
‘?
I
I
1)
/
;
/
~_
7Nm(0.7m~kg,5.1ft~Ib)
5-l
7 Nm (0.7
1-C i
10 Nm (1.0
m.kg,
5.1
USE NEW ONE
7.2
ft-lb)
m-kg,
ftelh)
1
]
1
RADIATOR
COOL %
REMOVAL
1. Remove:
?? Lower cowlings (Left and Right)
?? Side cowlings (Left and Right)
Refer to the “COWLING REMOVAL ANC
INSTALLATION - REMOVAL”
in the CHAPTER 3.
2. Drain:
0
Cooling system
Refer to the”COOLANT REPLACEMENT
section in the CHAPTER 3.
3. Remove:
?? Muffler assembly
NOTE:
Thoroughly flush the cooling system with
tap water.
ACAUTION:
Take care so that coolant does not splash 1
painted surfaces. If splashes, wash it
with water.
sectiol
cles
awi
Do not remove the radiator cap, drain bol
and hoses especially when the engine ar
radiator are hot. Scalding hot fluid and stea
may be blown out under pressure, which cou
cause serious injury. When the engine has
coole
place a thick rag like a towel over the radiat
cap, slowly rotate the cap counterclockwi
to the detent. This procedure allows any
pressure to escape. When the hissing sound
stopped, press down on the cap while
reside
r
turni
counterclockwise and remove it.
4. Disconnect:
?? Hose (Radiator
?? Hose (Radiator
-
Inlet)
-
Outlet)
@
@
5-2
6. Remove:
?? Fan motor assembly
INSPECTION
1. Inspect:
?? Radiator core
Obstruction + Blow out with compressed
air through rear of the radiator.
Flattened fin + Repair/replace.
2. Inspect:
?? Hose (Radiator
-
Inlet)
Cracks/Damage + Replace.
?? Hose (Radiator
-
Outlet)
Cracks/Damage + Replace.
0
Outlet pipe
Cracks/Damage
--f
Replace.
5-3
3. Measure:
?? Radiator cap opening pressure
Radiator cap opens at pressure below
specified pressure + Replace.
Radiator Cap Opening Pressure:
74 - 103
(0.75 - 1.05
kPa
kg/cm’,
10.7 - 14.9 psi)
the
Measurement steps:
@Attach
1
?? Apply the specified pressure for 10 seconds,
I
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Install:
the Cooling System Tester @ and
Adapter @ to the radiator cap @ .
Cooling System Tester:
Y U-24460-0 1
Adapter:
Y U-33984
and make sure there is no pressure drop.
?? Fan motor assembly
Screws (Fan Motor Assembly):
10 Nm (1.0 mm kg, 7.2
2. Install:
??
Radiator
Bolts (Radiator):
%’
3. Fill:
0
Cooling system
Refer to the “COOLANT REPLAC
MENT” section in the CHAPTER 3.
4. Inspect:
0
Cooling system
Decrease of pressure (leaks) + Repair
required.
7 Nm (0.7 me kg, 5.1
ft. lb)
ft. lb)
5-4
Inspection steps:
@Attach the Cooling System Tester @ to the
radiator.
Cooling System Tester:
Y U-24460-0 1
?? Apply 100
kPa
(1 .O
kg/cm*,
14 psi) pressure .
@Measure the indicated pressure with the
gauge.
5-5
WATER PUMP AND THERMOSTATIC VALVE
I
WATER PUMP AND THERMOSTATIC VALVE
0
@
Hose 3
ermostatic cover
@ Th
@
Thermostatic
@
Thermostatic housing
@
Hose 1
@
Hose 2
Pipe 2
@Pipe 1
@Water jacket joint
8 ($Jng
ring
@Water pipe
COOL
@O-ring
@Water pump cover
@O-ring
@Water
C@
THERMOSTATIC VALVE OPENING
pump housing
O-ring
/6 /
USE NEW ONE
B USE NEW ONE
~_
lnhlmfi nm.kn
I
73ft.lhl
/
5-6
WATER PUMP AND THERMOSTATIC VALVE
REMOVAL
1. Remove:
?? Lower cowlings (Left and right)
?? Center cowlings (Left and right)
0
Seat
?? Top cover
Refer to the “COWLING REMOVAL AND
INSTALLATION - REMOVAL” section
in the CHAPTER 3.
2. Drain:
0
Cooling system
Refer to
section in the CHAPTER 3.
the”COOLANT
COOL
r-ml
REPLACEMENT”
3. Remove:
?? Fuel tank
Refer to the
“CARBURETOR - RE-
MOVAL” section in the CHAPTER 6.
4. Disconnect:
?? Crankcase ventilation hose
lair
vent hose
@
@
5. Remove:
?? Air filter case
@
6. Disconnect:
whose
1
@
??
Hose2
@
??
Hose 3
@
WATER PUMP AND THERMOSTATIC VALVE
7. Disconnect:
??
Thermo unit lead
??
Thermo switch lead
8. Remove:
??
Thermostatic housing
@
COOL
rJ%l
@
9. Remove:
?? Thermostatic cover
?? Thermostatic
10. Remove:
??
Shift arm
??
Crankcase cover
11. Remove:
??
Water pipe
@
@
(Left)
0
5-8
WATER
PUMP
AND THERMOSTATIC
12. Remove:
@Water
0
13. Remove:
?? Water pump housing
@O-ring
pipe
Water pump cover
VALVE I-f
(Q
@
@
w
323 003
INSPECTION
1. Inspect:
?? Thermostatic valve
Valve does not open at 80 - 84°C (176
183” F)
+
Replace.
Inspection steps:
*Suspend thermostatic valve @ in a vessel
0.
?? Place reliable thermometer in a water
?? Head water slowly.
aObserve
water continually.
thermometer @ , while stirring
0.
NOTE:
Thermostatic valve is sealed and its setting is
specialized work. If its accuracy is in doubt,
always replace it. A faulty unit could cause
serious overheating or overcooling.
-
5-9
WATER PUMP AND THERMOSTATIC VALVE
2. Inspect:
0
Impeller
Cracks/Wear/Damage + Replace.
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Install:
0
Water pump cover
0 Pipe
?? Crankcase cover (Left)
o
Shift arm
??
Thermostatic cover
pqjiq
Bolts (Water Pump
Cover):
10 Nm (1.0 ma kg, 7.2
Bolts (Pipe) :
10 Nm (1.0 ma kg, 7.2
Bolts (Crankcase Cover - Left):
10 Nm (1.0 me kg, 7.2
Bolt (Shift Arm):
10 Nm (1.0 ma kg, 7.2
Bolts (Thermostatic Cover) :
10 Nm (1.0 m-kg, 7.2
~BCAWWN:
Always use new O-ring.
2. Fill:
0
Cooling system
Refer to the “COOLANT REPLACEMENT’
section in the CHAPTER 3.
3. Inspect:
0
Cooling system
Decrease of pressure (Leaks) + Repair as
required.
ftalb)
ft*lb)
ft*lb)
ft*Ib)
ftslb)
5-10
CARBURETOR
@
Upper bracket
@
Throttle stop screw
@
Fuel overflow hose
@
Lower bracket
ncronizing screw
0 SY
@
Float
0
Float pin
@
Float chamber
@
Needle jet
@
Fuel drain screw
CARBURETOR
0
Valve seat assembly
@
Pilot jet
@
Main jet
@
Starter plunger assembly
@
Pilot screw
@
Piston valve assembly
0
Jet needle set
@
Starter lever shaft
@
O-ring
CARBURETOR
r
ID Mark
MAIN JET
MAIN AIR JET
PI LOT JET
PILOT AIR JET
JET NEEDLE
PILOT SCREW
THROTTLE VALVE
ENGINE IDLE SPEED
FUEL LEVEL
SPEClf
piqq
CATIONS
3BF-00
(Except for California),
3FH-00
(For California)
#87.5
#60
#15
#I30
5CFZ2
3%
#I30
1,250 - 1,350
4.5 - 6.5 mm (0.18 - 0.26 ir
r/min
1 3 Nm (0.3 me kg, 2.2
ft.
lb)
6-1
CARBURETOR
I-
SECTION VIEW
@Starter air bleed
@
Starter air bleed pipe
@Air vent
@
Air inlet
@
Mixture outlet @Valve seat @Needle jet
@Starter plunger
@Starter jet No 1
@Starter jet No. 2 @Throttle valve
@Pilot air jet 2 @Bypass hole
@Main air jet @Pilot outlet
@)Pilot
air jet 1
@Fuel
inlet @Main jet
@Float needle valve @Main bleed pipe
@Pilot jet @Jet needle
@Float @Spring clip
@Pilot
@Piston
screw
valve
A
CAUtlON;
The pilot screw settings are adjusted fa
maximum performance at the factory.
Any attempt to change these settings
w
II decrease engine performance.
6-2
CARBURETOR
-1
REMOVAL
1. Remove:
0
Seat
a
Top cover
Refer to the “COWLING REMOVAL AND
INSTALLATION - REMOVAL” section
in the CHAPTER 3.
2. Turn the fuel cock to “OFF” position.
3. Remove:
?? Fuel cock lever
@
4. Disconnect:
?? Fuel hose
@
5. Remove:
?? Fuel pump
@
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
6. Remove:
?? Fuel tank bracket
@
7. Remove:
?? Fuel tank
@
6-3
CARBURETOR
8. Disconnect:
?? Crankcase ventilation hose
?? Air vent hose
9. Remove:
?? Air filter case
10. Loosen :
0
Screw (Starter cable clamp)
11. Disconnect:
??
Starter cable
@
@
@
CARB #
@
12. Disconnect:
?? Fuel hose
@
13. Loosen :
*Screws (Carburetor joint clamp -
0
14. Remove:
??
Carburetor assembly
15. Disconnect:
*Throttle cable 1
aThrottle
cable 2
@
@
UI
6-4
CARBURETOR
(CARBII
DISASSEMBLY
NOTE:
The following parts can be cleaned and inspected without carburetor separation.
?? Throttle valve
0
Piston valve
0
Starter plunger
?? Float chamber components
1. Remove:
*Bracket (Upper)
~Bracket
@Starter
(Lower)
lever shaft
@
@
@
2. Remove:
??????
?
*Spring 0
@Starter
plunger
@
3. Remove:
?? Vacuum chamber cover
??
Spring
@
?? Piston valve assembly
4. Remove:
?? Plug (Jet needle)
*Spring
??
aJet
@
Washer
needle
@
@I
@
@
0
6-5
CARBURETOR
[CARB(
5. Remove:
0
Pilot screw
6. Remove:
?? Float chamber cover
*Gasket
*Float pin
*Float
@Valve
*Valve
@
@
seat screw
seat assembly
@
@
7. Remove:
??
Main jet
@
?? Holder (Main jet)
??
Washer
@
0
Pilot jet
?? Needle jet
??
0
@
Pilot air jet
@
8
INSPECTION
1. Inspect:
?? Carburetor body
?? Float chamber
??
Fuel passage
Contamination + Clean as indicated.
Carburetor cleaning steps:
*Wash
carburetor in petroleum based
(Do not use any caustic carburetor
solution.
*Blow out all passages and jets with a
pressed air.
1
sol\
clea
6-6
2. Inspect:
??
Floats
Damage4
Replace.
CARBURETOR
~CARB~ j@ 1
3. Inspect:
*Float needle valve
0
Valve seat
??
O-ring
@
@
@
Damage/Wear/Contamination+Replace
a set.
4. Inspect:
*Throttle valve
Scratches-+Replace.
*Rubber diaphragm
Tears+ Replace.
as
5. Inspect:
??
Needle jet
?? Main jet
?? Holder
0
Pilot jet
??
Pilot adjust screw
0
Pilot air jet
@
@
@
@
@
@
Bends/Wear/Damage -+ Replace.
Contamination + Blow out jets with a
compressed air.
6. Check:
*Free movement
Insert the throttle valve into the carburetor
body, and check for free movement.
Stick- Replace.
6-7
CARBURETOR
ASSEMBLY
To assemble the carburetor, reverse the disassembly procedures. Note the following points.
??
Before reassembling, wash all parts in clean
gasoline.
??
Always use a new gasket.
1. Install:
??
Piton valve assembly
NOTE:
Note position of tab @ on diaphragm. This tab
must be placed in the cavity of the carburetor
body during reassembly.
2. Install:
??
Float chamber cover
*Vacuum chamber cover
3. Connect:
??
Throttle shaft
Throttle valves must be fully closed.
4. Install:
??
Starter lever shaft
CARBURETOR
pg-j
5. Installer:
*Upper
glower
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
bracket
bracket
@
@
Screw (Upper Bracket):
3 Nm (0.3 m-kg, 2.2
Screw (Lower Bracket):
5 Nm (0.5 m-kg, 3.6
ftelb)
ft.lb)
1. Install:
?? Fuel tank
@
Bolts (Fuel Tank):
14 Nm (1.4 ma kg, 10.2
2. Install:
?? Fuel tank bracket
Bolts (Fuel Tank Bracket):
10 Nm (1.0 m-kg, 7.2
3. Install:
?? Fuel pump
@
ft- lb)
@
ft.lb)
6-9
Bolt (Fuel Pump):
8 Nm (0.8 m -kg,
5.6 ft -
lb)
m
I &
n.5-6.5mm
CARBURETOR
ADJUSTMENT
NOTE:
Before adjusting the fuel level, the float heigl
should be
The pilot screw settings are adjusted f
maximum performance at the factory. A
attempt to change these settings
decrease enaine performance.
Fuel Level Adjustment
1. Measure:
.Fuel
adlusted.
level
@
Out of
specification+Adjust
ing adjustment steps.
it by the
folio
\II
Fuel level measurement steps:
?? Place the motorcycle on the level place.
?? Connect the Fuel Level Gauge
to the carburetor
?? Place the Gauge vertically next to the fl
chamber line @ .
?? Loosen the drain screw
?? Warm up the engine, then shut it off
few minutes.
?? fvleasure the fuel level. It should be
the specified range.
NOTE:
Fuel level readings of both side of
line should be equal.
0.
@
(YM-013
.
aft!
wii
carburN
6-10
CARBURETOR
(CARBI
2. Adjust:
??
Fuel level
Fuel level adjustment steps:
*Remove the carburetor assembly.
Refer to “REMOVAL” section.
*Remove the float, valve seat and the needle
valve.
??
inspect the valve seat and the needle valve.
If either is worn, replace as a set.
*If both are fine, adjust the float height by
bending the float tang
@Recheck the fuel level.
0.
6-11
FRONT WHEEL
@
Gear unit assembly @ Bearing
@
Oil seal
@
Meter clutch
@
Clutch retainer
@
Spacer
@
Collar
@
Wheel axle
CHASSIS
*
Load is the total weight of cargo, rider, passenger,anc
accessories.
FRONT WHEEL
-1
r
B
i 1.0 mm (0.04 in)
pii&G
1
lo/70 R17-53H
WEAR LIMIT:
-
i
1
7-l
1 RIM SIZE:
’
i MT3.00 X 17
D / RIM
I
-
RUNOUT
LIMIT:
I
/
FRONT WHEEL
Ml
REMOVAL
1. Place the motorcycle on a level place.
Securely support the motorcycle so there is no
danger of it falling over.
2, Remove:
?? Speedometer cable
3. Remove:
?? Brake calipers (Right/Left)
4. Loosen:
?? Pinch bolt (Front axle)
?? Axle (Front)
5. Elevate the front wheel by placing a suitablt
stand under the engine.
@
@
@
6. Remove:
??
Axle
@
?? Wheel (Front)
??
speedometer gear unit
NOTE:
Do not squeeze the brake lever while the wheel
off the motorcycle.
INSPECTION
1. Inspect:
??
Tire
Tire tread shows crosswise lines (minimun
tread
depth)/Cracks +
Minimum Tire Tread Depth:
1.0 mm (0.04 in)
w
I I
@
Tread depth @ Side wall @ Wear indicator
2. Inspect:
?? Front axle
Bends + Replace.
Roll the axle on a flat surface.
Repalce.
i!
dcl
34”
“08
Do not attempt to straighten a dent axle.
7-2
r
FRONT WHEEL
3. Inspect:
??
Wheel
Cracks/Bends/Warpage A
4. Measure:
??
Wheel
runout
Over specified limit + Repalce.
Rim
Runout
Radial @ : 2.0 mm (0.08 in)
Lateral @ : 2.0 mm (0.08 in)
@After
mounting a tire, ride conservatively to
allow proper tire to rim seating. Failure to do
so may cause an accident resulting in motor-
cycle damage and possible operator injury.
?? After a tire repair or replacement, be sure to
torque tighten the valve stem locknut @ to
specification.
-1
Replace.
Limits:
Valve-stem Locknut:
1.5 Nm (0.15
5. Inspect:
??
Wheel bearings
Bearings allow play in the wheel hub or
wheel turns roughly + Repalce.
Wheel bearing replacement steps:
?? Clean the outside of the wheel hub.
?? Remove the bearing using a general bearing
puller @I .
?? Install the new bearing by reversing the
previous steps.
rn.
kg, 1.1
ft.
lb)
I
7-3
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