Yamaha WR 400 PDF Installation Instruction Manual

1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!)
2. Remove the seat, side panels, and gas tank.
If you are color blind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you?
3. Unplug the yellow, blue and black taillight wires from the stock wiring harness.
4. Unplug the headlight from the stock wiring harness and remove.
5. Remove the kill switch. Unplug the black/white wire and the black wire from the connectors that were under the fuel tank.
6. Remove the headlight on/off switch. Unplug the three pin connector from its mate that was under the fuel tank.
7. Remove the stock AC voltage regulator (Photo 1) found mounted on the left side of the steering tube. Unplug its connector from the stock wiring harness

License Plate Mount Installation: Locate the aluminum license plate mount and license plate light assembly. If you have the alternative DOT taillight/license plate mount go to step 9B. Remove the rear most nut securing the stock taillight assembly (underneath the fender) (don’t lose the little compression tube and washer). Temporarily install the license plate mount to this location and mark the fender where it needs to be drilled for the rear mounts. Drill the fender in two places with a 1/4” drill and reinstall the license plate assembly using the stock taillight mount and the 6 x 20 mm countersunk screws, bezels and nylock nuts (Photo 2). Run the wires forward along with the taillight wires and up through the grommet in the fender.

Optional License Plate/DOT Taillight Installation: Remove the lens from the stock taillight. Remove the three nuts holding the gray taillight base
to the fender and remove base. Locate the 6 x 25 mm bolt supplied with other taillight mounting hardware (small bag #3) and a compression tube from the stock taillight (little brass colored tube that fits inside rubber grommet. Temporarily install the license plate bracket assembly using the rear most taillight mounting hole to determine the drill locations of the two rear mounts (You will have to remove the taillight temporarily to be able to mark the fender). Mark the fender and drill in two places with a 1/4” drill. Install the license plate hanger to the rear most mounts using the 6 x20 mm countersunk screws, bezels and nylock nuts. (Photo 3). Make sure to install the taillight ground wire under the nut for the left hand stud (Photo 4). Run the wires forward and up through the grommet in the fender.

A plastic cover is supplied to cover the opening left by the stock taillight. Transfer drill a hole in the fender for mounting the plastic cover. Install the compression tube provided between the cover and the bottom of the taillight well. Rear Turn Signal Installation: Turn signal mounting requires that you drill a 3/8 inch hole in either side of the rear fender near where it meets the side panels. You can achieve a clean, durable installation using this mounting location. Mount the rear turn signals by drilling a 3/8 hole in the rear fender in the location shown in Photo 5, 1-3/4 inches back from the front edge (edge just behind subframe) and 2-1/16 “ up from the bottom edge.

Run the left turn signal wires forward along with the taillight wires, up through the grommet in the fender to the area just behind the airbox cross member and above the fender. Run the right turn signal wires forward along the right frame rail, and up to the same location behind the airbox.

The WR 400 uses a hydraulic brake switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the rear brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic as failure to do it correctly will make the brake inoperable. Remove the rear master cylinder guard. Remove the bolt holding the brake fluid reservoir to provide access to the master cylinder. Loosen the banjo bolt securing the rear brake line to the master cylinder. Typically, this bolt will be very tight and loosening it will bend the support hanger for the master cylinder if not supported. Brace the master cylinder with a wrench or lever as shown in Photo 7.

Download Yamaha WR 400 PDF Installation Instruction Manual

 

Filed Under (Yamaha) by m4d35 on 15-04-2010
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