Date: 28-03-24  Time: 21:44 pm

Author Topic: 1997 FZ400  (Read 16012 times)

1997Fazer400

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1997 FZ400
« on: 16 November 2011, 12:58:26 pm »
Hi


I just bought a 1997 Fazer FZ400 and would like to get an owner's manual so I know how to do some basic servicing. Grateful for advice and where to get it please.


BR


Steve

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Re: 1997 FZ400
« Reply #1 on: 16 November 2011, 06:30:26 pm »
Hi and welcome. There are some manuals in our Downloads section here: http://foc-u.co.uk/index.php?action=downloads;cat=7

His Dudeness

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Re: 1997 FZ400
« Reply #2 on: 16 November 2011, 07:30:41 pm »
hey the internet actually works  :lol

steve could i ask how did you find this section? i attached the owners manual below. i forgot to add it in with the other stuff

1997Fazer400

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Re: 1997 FZ400
« Reply #3 on: 17 November 2011, 01:41:59 pm »
Yep, internet is amazing ain't it. :lol  Many thanks for posting the manual....unfortunately I dont read Japanese. Have you got the English version ? :'(
I found this section through google search on "FZ400 manual".

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Re: 1997 FZ400
« Reply #4 on: 17 November 2011, 11:49:55 pm »
No I don't have an English version. The bike was only meant for the Japanese market so there is no English version. BUT and its a big fat but. The fazer 600 manual is basically a copy and past of the original 400 manual. So if you open up the two of them side by side you can compare the sections. Just take the english from the 600 manual and the numbers from the Japanese 400 manual and you're sorted

1997Fazer400

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Re: 1997 FZ400
« Reply #5 on: 19 November 2011, 02:06:34 am »
Great !!! Many thx Dude, I got it, sorted !!! Fantastic site this :rolleyes   :lol

unfazed

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Re: 1997 FZ400
« Reply #6 on: 03 December 2011, 10:01:13 pm »
 Send me the code under the seat, it will be something like 4yrx 010 x and the frame number, it will be something like 4yr 00XXXXx (patj_duggan@yahoo.co.uk)
Then I can send you the exact parts catalogue. All parts are easy to get from the Yamaha dealers if you have the part number
 
Somebody has already uploaded the silver version catalogue and the converted word version of the owner’s manual I created some time ago. Unfortunately they were all in Japanese but I gave the parts file English names.
 
 I own a 2003 Fazer 600 and my eldest son had a 1997 Fazer 400 (4yr1) and now my youngest son has a 1998 4yr3 model.
 
The 400 is designated the FZ400 in Japan
 
Having both bikes in the garage I was able to compare them and during servicing and repairs I discovered the 400 is almost exactly the same as the 600 with the following main differences.
 
These major differences are:
The Carburettors
The Clocks
The Headlights.
The Lower fork sliders. (Stanchions are the same)
Fork Seals
Fork Seal dust caps
The Exhaust  (downpipes from 600 will fit)
The Air box cover (air filter is identical and worth fitting a K&N one, part number YA-6098)
The front of the air box and rubbers attaching to Carburettors
The Front Brake callipers and pads. (Discs are the same)
The Alternator ( Alternator and rotor from 600 will fit but you would need to change the plug on the connectors
The CDI unit
Intake manifolds (They do crack and leak and are about €40 each to replace)
Clutch basket and plates (A complete clutch from the 600 will fit.
 
The Oil Filter (same as 2002 to 2005 FZS1000) The 600 filter will fit and appears to work but is not correct.
 
The headlight bulbs are like H4 but you need to cut off two of the tabs to fit them
 
A good site for checking availability and prices using the part numbers is www.cmsnl.com
 
The centre stand of the 600 will fit straight on. The chain and sprockets are smaller in width but it is possible to fit the chain and sprockets from the 600. The front sprocket on the 400 has 14 teeth whereas the 600 has 15 teeth.
 
One thing to be aware is the front sprocket nut, it can fall off due to fretting of the threads in the nut and they wear away completely. However Yamaha upgraded the nut (appears to be a very well kept secret) and this is the part number for the lock nut kit 90891-10124. It is advisable to use thread lock when installing the nut and tighten it to over 70 NM. The drive chain slack should be 30 to 45mm and is easy to assume it is slack and over tighten it. If you do not have a centre stand sit two people on it when checking it. If you have a centre stand push the chain up against the rubber chain guard on the swinging arm and it should just touch the rubber on its tightest point.
It is worthwhile replacing the rear shock as the original is very soft with no damping and the fork springs. The 600 replacement options are a straight fit. 
If you have a problem with the lights being dull there was a recall on the 400 to replace a relay and fuses. If it was fixed there will be a circular sticker on the frame headstock with 500 written on it. It may also be the original bulbs as were 60/35 whereas all European H4 bulbs are 60/55.

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Re: 1997 FZ400
« Reply #7 on: 01 April 2012, 08:20:56 pm »
Friends, Greetings from Serbia.I have yamaha Fazer 400-4yr and I have a problem they can not can not find the cam chain and tenzioner.Da you accidentally corresponds with the same granite  fazer600.Thank for your help

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Re: 1997 FZ400
« Reply #8 on: 01 April 2012, 10:56:24 pm »
 Cam chain and tensioner are exactly the same as the 1998 to 2003 FZS 600. Yamaha only supply a full chain which would mean a full engine strip, but ones with split links are available.
Yamaha part number is 94591-47130 and is the same for both 400 and 600 bikes.
DID part number is 92RH2010 x130 links. Tensioner for both bikes have different part numbers but this is because the upgraded the spring of the 600 tensioner.
You can purchase a cam chain with split link from www.wemoto.co.uk. I purchased and fitted one of these chains to my 600 over 2 years ago. A slow awkward but not overly difficult job.
A good site to check Yamaha spares availability is www.cmsnl.com
What is wrong with the tensioner? I have never heard of them giving problems. If the chain is rattling then it is most likely that the chain is worn and the tensioner has come to the end of its adjustable range. If you do have to purchase a tensioner then a good secondhand one off a low mileage 600 if possible would be your cheapest option. New tensioners are over £120.
« Last Edit: 01 April 2012, 10:58:38 pm by unfazed »

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Re: 1997 FZ400
« Reply #9 on: 03 April 2012, 12:13:05 am »
Thanks for yor quick explanation and instructions from Unfazed.J hope that J have found on german ebay from fzs  600 tensioner 2002/2003 rj2 and cum chain from 99 fzs 600 used 27000 km.J found on wemoto cum chain new.J buy used if sellers from Germany wants to send to Serbia.Once again very grateful for your efforts and the Council.J hope that my fazer go on the road for couple week with this parts.

unfazed

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Re: 1997 FZ400
« Reply #10 on: 03 April 2012, 06:12:12 pm »
Do not fit a used cam chain as it is false economy.  BUY A NEW CAM CHAIN
http://www.wemoto.com/bikes/yamaha/fzs_600_fazer/98-99/picture/cam_timing_chain_tourmax_-_rivet_link/
http://www.wemoto.com/bikes/yamaha/fzs_600_fazer/98-99/picture/cam_timing_chain_tourmax/
Remove the tensioner and check it is moving freely oil it well and highly unlikely you will need to change it.
 

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Re: 1997 FZ400
« Reply #11 on: 03 April 2012, 07:43:10 pm »
I have an engine with a tensioner, chain, cams etc. going spare
The Frying Scotsman

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Re: 1997 FZ400
« Reply #12 on: 05 June 2013, 10:27:46 am »
Cam chain and tensioner are exactly the same as the 1998 to 2003 FZS 600. Yamaha only supply a full chain which would mean a full engine strip, but ones with split links are available.
Yamaha part number is 94591-47130 and is the same for both 400 and 600 bikes.
DID part number is 92RH2010 x130 links. Tensioner for both bikes have different part numbers but this is because the upgraded the spring of the 600 tensioner.
You can purchase a cam chain with split link from www.wemoto.co.uk. I purchased and fitted one of these chains to my 600 over 2 years ago. A slow awkward but not overly difficult job.
A good site to check Yamaha spares availability is www.cmsnl.com
What is wrong with the tensioner? I have never heard of them giving problems. If the chain is rattling then it is most likely that the chain is worn and the tensioner has come to the end of its adjustable range. If you do have to purchase a tensioner then a good secondhand one off a low mileage 600 if possible would be your cheapest option. New tensioners are over £120.



sorry to hijack





will a 1986 fz400 tensioner fit a 2003 fzs600? or do you think parts are interchangeable?
i have worn the backing off my intake chain damper and this may be a solution.


thanks

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Re: 1997 FZ400
« Reply #13 on: 05 June 2013, 11:09:58 pm »
I would not think so, it may fit in the hole but it looks to short
What exactly do you mean by "I have worn the backing off my intake chain damper and this may be a solution."?
Ther are plenty of FZS600 ones on ebay at reasonable prices


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Re: 1997 FZ400
« Reply #14 on: 06 June 2013, 09:36:50 am »
I would not think so, it may fit in the hole but it looks to short
What exactly do you mean by "I have worn the backing off my intake chain damper and this may be a solution."?
Ther are plenty of FZS600 ones on ebay at reasonable prices


i mean this, think this combined with a worn tensioner could be the source of my rattle.





photo taken down the tensioner hole, looks like the damping material on the intake side cam chain damper has worn away.
my intention is to modify or build a manual tensioner with some damping material on the end. failing that i'll have to split the case and replace it  :(
« Last Edit: 06 June 2013, 09:39:03 am by markaboot »

unfazed

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Re: 1997 FZ400
« Reply #15 on: 06 June 2013, 08:55:24 pm »
What you are seeing there is normal as there is no material on the end of the tensioner. Put the tensioner back in and remove the alternator cover and turn the engine anti clockwise and you may hear the tensioner click into place as it takes up the chain slack. Post a picture of the original tensioner you removed before putting it back in.
It is most likely a stretched cam chain and tensioner is at the end of it adjustment. The best way to check for a worn chain is to remove the cam cover and see if all three timing marks line up. two on the cams and one on the rotor. If they don't line up correctly then the chain is worn.
« Last Edit: 06 June 2013, 10:08:59 pm by unfazed »

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Re: 1997 FZ400
« Reply #16 on: 07 June 2013, 10:42:53 am »
What you are seeing there is normal as there is no material on the end of the tensioner. Put the tensioner back in and remove the alternator cover and turn the engine anti clockwise and you may hear the tensioner click into place as it takes up the chain slack. Post a picture of the original tensioner you removed before putting it back in.
It is most likely a stretched cam chain and tensioner is at the end of it adjustment. The best way to check for a worn chain is to remove the cam cover and see if all three timing marks line up. two on the cams and one on the rotor. If they don't line up correctly then the chain is worn.


its just had a brand new chain, still rattles  :(

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Re: 1997 FZ400
« Reply #17 on: 07 June 2013, 07:53:46 pm »
A few questions
What mileage is on the engine?
Is the tensioner working correctly?  They rarely fail but can stick from lack of use (Rust). Does it move in and out freely with the ratchet off the splines. Are all the pieces including the ball bearing back in the correct order?
Were all the valve clearances set correctly and the cam shaft caps put back in the correct positions
Does the chain have the right number of links? 130 incuding the soft link, it would not be the first time I have seen somebody fit the wrong length chain.
I think you will have to recheck everthing metodically even down to counting the number of links.
The only thing I came accross many years ago on a  honda which caused the chain to rattle after installing a brand new one was a damper which had gone soft., but I have never heard of it happening on a fazer.
 
 

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Re: 1997 FZ400
« Reply #18 on: 13 June 2013, 10:09:18 am »
A few questions
What mileage is on the engine?
Is the tensioner working correctly?  They rarely fail but can stick from lack of use (Rust). Does it move in and out freely with the ratchet off the splines. Are all the pieces including the ball bearing back in the correct order?
Were all the valve clearances set correctly and the cam shaft caps put back in the correct positions
Does the chain have the right number of links? 130 incuding the soft link, it would not be the first time I have seen somebody fit the wrong length chain.
I think you will have to recheck everthing metodically even down to counting the number of links.
The only thing I came accross many years ago on a  honda which caused the chain to rattle after installing a brand new one was a damper which had gone soft., but I have never heard of it happening on a fazer.


i've just gone over 20000 miles its an 03 fzs600
the tensioner is not sticking, looks clean as a whistle, yep bearings springs back in, even tried the extra bearing trick but no luck.
valve clearances were checked and all within tollerance


now chain links did pop into my head as I didnt do the chain myself, next time i get chance to take the cover off i'll see if i have more than 130 links


im going to replace the springs in the tensioner with a rod the correct length, making it a manual tensioner effectively and removing the slight play. just to rule out the tensioner as a problem.


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Re: 1997 FZ400
« Reply #19 on: 13 June 2013, 11:50:31 pm »
I would not recommend it, the tensioner has a max limit that it will not go beyond. when it reaches the limit the chain rattles as it cannot take up anymore slack. Putting a rod in the back will not do anything. Put a few hours aside and check the cam timing and number of links as stated previously.