2001 YAMAHA WR 400F brake

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 its pipe por-
tion a directs as show and lightly touches
the projection b on the master cylinder.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
EC5A5500
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 master cylinder.
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.
New
New
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.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
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

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
lMaster cylinder cap 1
lScrew (master cylinder cap) 2
[Rear]
lDiaphragm
lReservoir tank cap 1
lScrew (reservoir tank cap) 2
lMaster cylinder guard
CAUTION:
After installation, while pulling the lever in
or pushing down on the pedal, check
whether there is any brake fluid leaking
where the union bolts are installed respec-
tively at the master cylinder and 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 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 (handle crown) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (under bracket) 2 Only loosening.
6 Front fork 1
1

5 - 40
CHASFRONT FORK
4. Tighten:
lPinch bolt (handle crown) 1
lPinch bolt (under bracket) 2
CAUTION:
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. 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.
6. Install:
lBrake hose holder 1
lBolt (brake hose holder) 2
lProtector 3
lBolt (protector) 4
NOTE:
When installing the brake hose holder, pass
the brake hose 5 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..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Adjust:
lRebound damping force
NOTE:
Turn in the damping adjuster 1 finger-tight
and then turn out to the originally set position.

5 - 42
CHAS
EC5B3000
REMOVAL POINTS
EC5B3100
Master cylinder
1. Remove:
lMaster cylinder bracket 1
lMaster cylinder 2
CAUTION:
lDo not let the master cylinder hang on the
brake hose.
lKeep the master cylinder cap side hori-
zontal to prevent air from coming in.
EC5B3200
Grip
1. Remove:
lGrip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
EC5B4000
INSPECTION
EC5B4100
Handlebar
1. Inspect:
lHandlebar 1
Bends/cracks/damage ® Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
EC5B5000
ASSEMBLY AND INSTALLATION
Handlebar
1. Install:
lHandlebar 1
lHandlebar holder 2
lBolt (handlebar holder) 3
NOTE:
lThe upper handlebar holder should be
installed with the punched mark a forward.
lFirst tighten the bolts on the front side of the
handlebar holder, and then tighten the bolts
on the rear side.
T R..28 Nm (2.8 m · kg, 20 ft · lb)
HANDLEBAR

5 - 52
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Chain support 1
2 Chain tensioner (lower) 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6Swingarm
1
1