2001 YAMAHA WR 400F brake

5 - 17
CHAS
EC534214
Caliper
1. Inspect:
lCaliper cylinder inner surface a
Wear/score marks ® Replace caliper
assembly.
Front
õRear
õ
2. Inspect:
lCaliper piston 1
Wear/score marks ® Replace caliper
piston assembly.
WARNING
Replace the piston seals and dust seals 2
whenever a caliper is disassembled.
EC534301
Brake hose
1. Inspect:
lBrake hose 1
Crack/damage ® Replace.
EC5A5000
ASSEMBLY AND INSTALLATION
WARNING
lAll internal parts should be cleaned in
new brake fluid only.
lInternal parts should be lubricated with
brake fluid when installed.
lReplace the piston seals and dust seals
whenever a caliper is disassembled.
EC5A5800
Caliper piston
1. Clean:
lCaliper
lPiston seal
lDust seal
lCaliper piston
Clean them with brake fluid.
FRONT BRAKE AND REAR BRAKE

5 - 18
CHAS
2. Install:
lPiston seal 1
lDust seal 2
WARNING
Always use new piston seals and dust
seals.
NOTE:
Fit the piston seals and dust seals onto the slot
on caliper correctly.
Front
õRear

New
New
õ
FRONT BRAKE AND REAR BRAKE
3. Install:
lCaliper piston 1
NOTE:
Apply the brake fluid on the piston wall.
CAUTION:
lFor the front caliper, install the piston
with its depressed side a facing the cali-
per. For the rear caliper, install the piston
with its shallow depressed side b facing
the caliper.
lNever force to insert.
Front
õRear
EC5A5700
Front caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pads with their projections
a into the caliper recesses b.
lTemporarily tighten the pad pin at this point.

õ

5 - 19
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lCopper washer 1
lUnion bolt 2
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
lBrake hose holder 1
lCaliper 2
lBolt (caliper) 3
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
4. Tighten:
lPad pin 4
5. Install:
lPad pin plug 5
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)
EC5A5100
Rear caliper
1. Install:
lPad support 1
lBrake pad 2
lPad pin 3
NOTE:
lInstall the brake pads with their projections
a into the caliper recesses b.
lTemporarily tighten the pad pin at this point.

5 - 20
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lDisc cover 1
lBolt (disc cover) 2
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose to the caliper with the
paint a on the pipe facing the caliper and
with the pipe contacting the caliper projec-
tion b.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:
lCaliper 1
lRear wheel 2
Refer to “FRONT WHEEL AND REAR
WHEEL” section.
5. Tighten:
lPad pin 3
6. Install:
lPad pin plug 4
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)

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

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
lMaster cylinder kit 1
lPlain washer 2
lCirclip 3
lMaster cylinder boot 4
To master cylinder 5.
[Rear]
lMaster cylinder kit 1
lPush rod 2
lCirclip 3
lMaster cylinder boot 4
To master cylinder 5.
NOTE:
lApply the brake fluid on the 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
EC5A5310
Front master cylinder
1. Install:
lMaster cylinder 1
lMaster cylinder bracket 2
lBolt (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
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 master cylinder piston.
Rear 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:
lMaster cylinder 1
lBolt (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.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 24
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
lPin 1
lPlain washer 2
lCotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
New
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).
2. Install:
lHose cover 1
lPlain washer 2
lBolt [hose cover (M8)] 3
lBolt [hose cover (M6)] 4
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
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
guide 1, then through the guide a on
the protector 2.