2001 YAMAHA WR 250F brake

5 - 21
CHASFRONT BRAKE AND REAR BRAKE
Brake master cylinder kit
1. Clean:
lBrake master cylinder
lBrake master cylinder kit
Clean them with brake fluid.
2. Install:
lBrake master cylinder cup (primary) 1
lBrake master cylinder cup (secondary)
2
To brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cyl-
inder cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
Front
õRear
õ

3. Install:
lSpring 1
To brake master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
Front
õRear

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
lBrake master cylinder kit 1
lWasher 2
lCirclip 3
lBrake master cylinder boot 4
To brake master cylinder 5.
[Rear]
lBrake master cylinder kit 1
lPush rod 2
lCirclip 3
lBrake master cylinder boot 4
To brake master cylinder 5.
NOTE:
lApply the brake fluid on the brake master
cylinder kit.
lApply the lithium soap base grease on the tip
of the push rod.
lWhen installing the circlip, use a long nose
circlip pliers.
Front
õRear

õ
Front brake master cylinder
1. Install:
lBrake master cylinder 1
lBrake master cylinder bracket 2
lBolt (brake master cylinder bracket) 3
NOTE:
lInstall the bracket so that the arrow mark a
face upward.
lFirst tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lBrake lever 1
lBolt (brake lever) 2
lNut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the brake master cylinder piston.
Rear brake master cylinder
1. Install:
lReservoir hose 1
lReservoir tank 2
lBolt (reservoir tank) 3
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
lBrake master cylinder 1
lBolt (brake master cylinder) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
lSpring 1
lBrake pedal 2
lO-ring 3
lBolt (brake pedal) 4
lClip 5
NOTE:
lApply the lithium soap base grease on the
bolt, O-ring and brake pedal bracket.
lInstall the clip with its stopper portion a fac-
ing inward.
T R..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 24
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
lPin 1
lWasher 2
lCotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
Front brake hose
1. Install:
lBrake hose 1
To brake hose holder 2.
NOTE:
Before tightening the bolt (brake hose holder),
pass the brake hose in front of the axle boss
a, then fit it into the hose groove b so that the
brake hose does not contact the nut (wheel
axle).
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
lBrake hose cover 1
lWasher 2
lBolt [brake hose cover (M8)] 3
lBolt [brake hose cover (M6)] 4
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Pass the brake hose through the cable
guides 1, then through the guides a on
the protector 2.

5 - 25
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that it contacts
the master cylinder projection a and that
its bent portion b faces downward.
T R..30 Nm (3.0 m · kg, 22 ft · lb)
Rear brake hose
1. Install:
lCopper washer 1
lBrake hose 2
lCopper washer 3
lUnion bolt 4
WARNING
Always use new copper washers.
CAUTION:
When installing the brake hose, first align
the tooth a on the copper washer 1 with
the projection b on the brake master cylin-
der. Then, align the pipe portion c on the
end of the brake hose with the tooth d on
the copper washer 1 and tighten the union
bolt.
T R..30 Nm (3.0 m · kg, 22 ft · lb)

5 - 26
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lBrake hose holder 1
lScrew (brake hose holder) 2
CAUTION:
After installing the brake hose holders,
make sure the brake hose does not contact
the spring (rear shock absorber). If it does,
correct its twist.
Brake fluid
1. Fill:
lBrake fluid
Until the fluid level reaches “LOWER”
level line a.
WARNING
lUse only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
lRefill with the same type of brake fluid;
mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
lBe careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
Front
õRear
Recommended brake fluid:
DOT #4
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

õ

5 - 27
CHASFRONT BRAKE AND REAR BRAKE
2. Air bleed:
lBrake system
Refer to “BRAKE SYSTEM AIR
BLEEDING” section in the CHAPTER
3.
3. Inspect:
lBrake fluid level
Fluid at lower level ® Fill up.
Refer to “BRAKE FLUID LEVEL
INSPECTION” section in the CHAP-
TER 3.
4. Install:
[Front]
lDiaphragm
lBrake master cylinder cap 1
lScrew (brake master cylinder cap) 2
[Rear]
lDiaphragm
lReservoir tank cap 1
lScrew (reservoir tank cap) 2
lBrake master cylinder guard
CAUTION:
After installation, while pulling the brake
lever in or pushing down on the brake
pedal, check whether there is any brake
fluid leaking where the union bolts are
installed respectively at the brake master
cylinder and brake caliper.
Front
õRear
5. Install: (rear brake only)
lProtector 1
lBolt (protector) 2

T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
õ
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

5 - 28
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front brake caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (upper bracket) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (lower bracket) 2 Only loosening.
6 Front fork 1
1