Yamaha WR400 WR400F 2000-2008 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Yamaha Model: WR400F Model Designation: WR400 Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 Codes Engine Code Identifier: Likely a 4SP designation for 4-stroke, specific engine code not provided but consistent across years for this model line Chassis Code Identifier: Specific chassis codes vary by year and region but the manual covers the WR400F platform across this range 👋 Introduction Market Position Vehicle Type: Competition Motocross/Enduro Motorcycle Competitive Analysis Key Competitors Era: KTM EXC, Honda CR, Kawasaki KX, Suzuki RM Key Features Manual Value Proposition: Comprehensive, accurate, and detailed technical information for DIY mechanics and professional technicians, enabling cost savings on repairs and maintenance. Digital Manual Advantage: No risk of damage from oil/dirt, ability to print specific sections, instant access Manual Completeness Assurance: Guaranteed to be complete and intact, without missing or corrupt parts/pages. 📋 Manual Details Coverage Areas Coverage Scope: All Models, All Engines, All Trim Types, All Transmission Types Page Count Estimated Page Count: Hundreds of pages (as stated in product description) Manual Type Type: Workshop Repair Service Manual Origin Of Manual: OEM (Original Equipment Manufacturer) equivalent, same manual used in official service/repair shops. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Covered Systems: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix Electrical System Detail: Includes detailed wiring diagrams, troubleshooting for ignition, lighting, and charging systems. Suspension Details: Covers front forks (likely upside-down telescopic) and rear monoshock suspension, including adjustment and maintenance. Brake System Details: Detailed information on hydraulic brake system components, including fluid replacement, caliper service, and pad replacement. Wheel Tire Final Drive Details: Includes information on wheel bearing maintenance, tire pressure, and chain drive adjustment/lubrication. Procedures Included Included Procedures: Service, Maintenance, Troubleshooting, Repair, Disassembly, Assembly, Cleaning, Reinstalling Procedures, Diagnostic information, Electrical service procedures, Wiring diagrams Engine Rebuild Procedures: Complete procedures for engine top-end rebuild, crankshaft and transmission disassembly/assembly. Troubleshooting Electrical: Specific troubleshooting guides for electrical system faults, often integrated with wiring diagrams. Technical Depth Depth Of Information: Professional-level diagnostic, repair, and maintenance information as used by local service/repair shops; detailed substeps, critical specifications, critical information (notes, cautions, warnings) Diagnostic Capabilities: Comprehensive diagnostics for all major systems, including specific procedures for identifying and resolving faults. 📊 Manual Specifications File Format File Format Details: PDF Searchability: PDF format typically allows for text searching, enhancing usability for finding specific information quickly. Print Quality Printability: Full Printable Zoom Functionality Zoom Capability: YES Delivery Method Delivery: Instant Download Software Requirements Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke Engine Displacement: Approximately 396cc (specific bore/stroke not provided, but characteristic of WR400F) Engine Bore Stroke Typical: Typical bore around 84mm and stroke around 70mm for this displacement. Performance Horsepower Estimated: Likely in the 40-45 HP range (typical for this class and era) Torque Estimated: Not specified, but optimized for off-road usability Fuel System Fuel Delivery: Carbureted (likely Mikuni VM series, specific model not provided) Carburetor Considerations: Manual likely details specific carburetor tuning, jetting, and cleaning procedures. Cooling System Cooling Method: Liquid-Cooled 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Optional Transmissions: N/A (standard for this model) Features Clutch Type: Wet, multi-plate 📐 Dimensions Exterior Wheelbase: Varies slightly by year, typically around 1475-1485 mm (58.1-58.5 inches) Ground Clearance: Typically around 330-345 mm (13-13.6 inches) Seat Height: Approximately 960-970 mm (37.8-38.2 inches) Weights Dry Weight: Approximately 115-117 kg (253-258 lbs) Wet Weight: Not specified, but includes fluids 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles typically do not have NHTSA/Euro NCAP ratings) Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Frame Construction: Steel semi-double cradle frame 💡 Technology Features Infotainment Infotainment Features: N/A (Competition off-road motorcycle, no infotainment systems) Driver Assistance Rider Assistance: Focus on mechanical systems for performance and reliability. No electronic rider aids beyond basic ignition and lighting. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/hour recommendations (typically every 10-20 hours of use or 1000-2000 miles for severe off-road use) Air Filter Cleaning: Frequent cleaning/replacement recommended, especially in dusty conditions (refer to manual) Fluid Specifications Engine Oil Type: Yamalube (or equivalent SAE 10W-40 API SG or higher, JASO MA rated motorcycle oil) Coolant Type: Permanent type antifreeze (ethylene glycol base) with distilled water (50/50 mix) Transmission Oil Type: Yamalube (or equivalent SAE 75W API GL-4 or GL-5 gear oil, depending on specific gearbox design) Known Issues Common Wear Items: Clutch wear, spark plug fouling, air filter degradation, potential carburetor jetting issues, valve clearance adjustments Troubleshooting Focus: The manual's troubleshooting section is crucial for addressing performance issues, starting problems, and electrical gremlins. Carburetor Maintenance Focus: The...
Likely a 4SP designation for 4-stroke, specific engine code not provided but consistent across years for this model line
Chassis Code Identifier:
Specific chassis codes vary by year and region but the manual covers the WR400F platform across this range
👋 Introduction
Market Position
Vehicle Type:
Competition Motocross/Enduro Motorcycle
Competitive Analysis
Key Competitors Era:
KTM EXC, Honda CR, Kawasaki KX, Suzuki RM
Key Features
Manual Value Proposition:
Comprehensive, accurate, and detailed technical information for DIY mechanics and professional technicians, enabling cost savings on repairs and maintenance.
Digital Manual Advantage:
No risk of damage from oil/dirt, ability to print specific sections, instant access
Manual Completeness Assurance:
Guaranteed to be complete and intact, without missing or corrupt parts/pages.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models, All Engines, All Trim Types, All Transmission Types
Page Count
Estimated Page Count:
Hundreds of pages (as stated in product description)
Manual Type
Type:
Workshop Repair Service Manual
Origin Of Manual:
OEM (Original Equipment Manufacturer) equivalent, same manual used in official service/repair shops.
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Covered Systems:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Electrical System Detail:
Includes detailed wiring diagrams, troubleshooting for ignition, lighting, and charging systems.
Suspension Details:
Covers front forks (likely upside-down telescopic) and rear monoshock suspension, including adjustment and maintenance.
Brake System Details:
Detailed information on hydraulic brake system components, including fluid replacement, caliper service, and pad replacement.
Wheel Tire Final Drive Details:
Includes information on wheel bearing maintenance, tire pressure, and chain drive adjustment/lubrication.
Complete procedures for engine top-end rebuild, crankshaft and transmission disassembly/assembly.
Troubleshooting Electrical:
Specific troubleshooting guides for electrical system faults, often integrated with wiring diagrams.
Technical Depth
Depth Of Information:
Professional-level diagnostic, repair, and maintenance information as used by local service/repair shops; detailed substeps, critical specifications, critical information (notes, cautions, warnings)
Diagnostic Capabilities:
Comprehensive diagnostics for all major systems, including specific procedures for identifying and resolving faults.
📊 Manual Specifications
File Format
File Format Details:
PDF
Searchability:
PDF format typically allows for text searching, enhancing usability for finding specific information quickly.
Print Quality
Printability:
Full Printable
Zoom Functionality
Zoom Capability:
YES
Delivery Method
Delivery:
Instant Download
Software Requirements
Requirements:
Adobe PDF Reader, WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke
Engine Displacement:
Approximately 396cc (specific bore/stroke not provided, but characteristic of WR400F)
Engine Bore Stroke Typical:
Typical bore around 84mm and stroke around 70mm for this displacement.
Performance
Horsepower Estimated:
Likely in the 40-45 HP range (typical for this class and era)
Torque Estimated:
Not specified, but optimized for off-road usability
Fuel System
Fuel Delivery:
Carbureted (likely Mikuni VM series, specific model not provided)
Carburetor Considerations:
Manual likely details specific carburetor tuning, jetting, and cleaning procedures.
Cooling System
Cooling Method:
Liquid-Cooled
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Optional Transmissions:
N/A (standard for this model)
Features
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Wheelbase:
Varies slightly by year, typically around 1475-1485 mm (58.1-58.5 inches)
Ground Clearance:
Typically around 330-345 mm (13-13.6 inches)
Seat Height:
Approximately 960-970 mm (37.8-38.2 inches)
Weights
Dry Weight:
Approximately 115-117 kg (253-258 lbs)
Wet Weight:
Not specified, but includes fluids
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles typically do not have NHTSA/Euro NCAP ratings)
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Frame Construction:
Steel semi-double cradle frame
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Competition off-road motorcycle, no infotainment systems)
Driver Assistance
Rider Assistance:
Focus on mechanical systems for performance and reliability. No electronic rider aids beyond basic ignition and lighting.
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/hour recommendations (typically every 10-20 hours of use or 1000-2000 miles for severe off-road use)
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially in dusty conditions (refer to manual)
Fluid Specifications
Engine Oil Type:
Yamalube (or equivalent SAE 10W-40 API SG or higher, JASO MA rated motorcycle oil)
Coolant Type:
Permanent type antifreeze (ethylene glycol base) with distilled water (50/50 mix)
Transmission Oil Type:
Yamalube (or equivalent SAE 75W API GL-4 or GL-5 gear oil, depending on specific gearbox design)
The manual's troubleshooting section is crucial for addressing performance issues, starting problems, and electrical gremlins.
Carburetor Maintenance Focus:
The manual's detail on the fuel system is critical for addressing performance tuning and maintenance of the carburetor.
📚 Vehicle History
Brand Heritage
Yamaha Offroad Legacy:
Yamaha has a long and successful history in off-road racing and motocross, dating back to the YZ series. The WR line continues this heritage with features optimized for enduro riding.
Model Evolution
Wr400F Development:
The WR400F was introduced as a competition enduro model, evolving from Yamaha's motocross technology. It featured a potent four-stroke engine designed for broad power delivery suitable for various off-road conditions.
Wr400F Market Segment:
Positioned as a competitive off-road machine, bridging the gap between motocross-specific models and street-legal dual-sports.
Production
Production Period:
The WR400F was produced for a significant period, with this manual covering a substantial generational update from 2000 to 2008.
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