2007 YAMAHA WR 450F brake

5 - 12
CHAS
EC5A8200
CALIPER DISASSEMBLY
ÈFront
ÉRear
Extent of removal:
1 Front caliper disassembly
2 Rear caliper disassembly
Extent of removal Order Part name Q’ty Remarks
CALIPER DISASSEMBLYAB
1 Pad pin 1 1
2 Brake pad 2 2
3 Pad support 1 1
4 Caliper piston 2 1
Refer to “REMOVAL POINTS”.
5 Dust seal 2 1
6 Piston seal 2 1
21
FRONT BRAKE AND REAR BRAKE

5 - 13
CHASFRONT BRAKE AND REAR BRAKE
EC5A8300
MASTER CYLINDER DISASSEMBLY
ÈFront
ÉRear
Extent of removal:
1 Front master cylinder disassembly
2 Rear master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
MASTER CYLINDER DISAS-
SEMBLY
1 Master cylinder cap 1
2 Diaphragm 1
3 Reservoir float 1
4 Master cylinder boot 1
5 Circlip 1 Use a long nose circlip pliers.
6 Plain washer 1
7 Push rod 1
8 Master cylinder kit 1
1
1
2
2
2

5 - 14
CHASFRONT BRAKE AND REAR BRAKE
EC5A3000
REMOVAL POINTS
Brake fluid
1. Remove:
[Front]
Master cylinder cap 1
[Rear]
Master cylinder cap 1
Protector
NOTE:
Do not remove the diaphragm.
ÈFront
ÉRear
2. Connect the transparent hose 2 to the
bleed screw 1 and place a suitable con-
tainer under its end.
ÈFront
ÉRear
È
É
3. Loosen the bleed screw and drain the
brake fluid while pulling the lever in or
pushing down on the pedal.
CAUTION:
Do not reuse the drained brake fluid.
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled
fluid immediately.
EC533301
Caliper piston
1. Remove:
Caliper piston
Use compressed air and proceed care-
fully.
WARNING
Cover piston with rag and use extreme
caution when expelling piston from cylin-
der.
Never attempt to pry out piston.
ÈFront
ÉRear
Caliper piston removal steps:
Insert a piece of rag into the caliper to lock
one caliper.
Carefully force the piston out of the caliper
cylinder with compressed air.
ÈÉ
È
É

5 - 15
CHASFRONT BRAKE AND REAR BRAKE
EC533402
Piston seal kit
1. Remove:
Dust seal 1
Piston seal 2
NOTE:
Remove the piston seals and dust seals by
pushing them with a finger.
CAUTION:
Never attempt to pry out piston seals and
dust seals.
WARNING
Replace the piston seals and dust seals
whenever a caliper is disassembled.
ÈFront
ÉRear
È
É
EC5A4000
INSPECTION
EC534112
Master cylinder
1. Inspect:
Master cylinder inner surface
a
Wear/scratches → Replace master cylin-
der assembly.
Stains → Clean.
WARNING
Use only new brake fluid.
ÈFront
ÉRear
2. Inspect:
Diaphragm 1
Crack/damage → Replace.
ÈFront
ÉRear
ÈÉ
ÈÉ
3. Inspect: (front brake only)
Reservoir float 1
Damage → Replace.

5 - 16
CHAS
4. Inspect:
Master cylinder piston 1
Master cylinder cup 2
Wear/damage/score marks → Replace
master cylinder kit.
ÈFront
ÉRear
ÈÉ
EC534214
Caliper
1. Inspect:
Caliper cylinder inner surface
a
Wear/score marks → Replace caliper
assembly.
ÈFront
ÉRear
ÈÉ
2. Inspect:
Caliper piston 1
Wear/score marks → Replace caliper pis-
ton assembly.
WARNING
Replace the piston seals and dust seals 2
whenever a caliper is disassembled.
EC534301
Brake hose
1. Inspect:
Brake hose 1
Crack/damage → Replace.
EC5A5000
ASSEMBLY AND INSTALLATION
WARNING
All internal parts should be cleaned in
new brake fluid only.
Internal parts should be lubricated with
brake fluid when installed.
Replace the piston seals and dust seals
whenever a caliper is disassembled.
FRONT BRAKE AND REAR BRAKE

5 - 17
CHAS
EC5A5800
Caliper piston
1. Clean:
Caliper
Piston seal
Dust seal
Caliper piston
Clean them with brake fluid.
2. Install:
Piston seal 1
Dust 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.
ÈFront
ÉRear
3. Install:
Caliper piston 1
NOTE:
Apply the brake fluid on the piston wall.
CAUTION:
Install the piston with its shallow
depressed side
a facing the caliper.
Never force to insert.
ÈFront
ÉRear
Front caliper
1. Install:
Pad support 1
Brake pad 2
Pad pin 3
NOTE:
Install the brake pads with their projections
a into the caliper recesses
b.
Temporarily tighten the pad pin at this point.
È
New
New
É
È
É
FRONT BRAKE AND REAR BRAKE

5 - 18
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Caliper 1
Bolt (caliper) 2
3. Tighten:
Pad pin 3
4. Install:
Pad pin plug 4
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:
Pad support 1
Brake pad 2
Pad pin 3
NOTE:
Install the brake pads with their projections
a into the caliper recesses b.
Temporarily tighten the pad pin at this point.
2. Install:
Disc cover 1
Bolt (disc cover) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

5 - 19
CHASFRONT BRAKE AND REAR BRAKE
3. Install:
Caliper 1
Rear wheel 2
Refer to “FRONT WHEEL AND REAR
WHEEL” section.
4. Tighten:
Pad pin 3
5. Install:
Pad pin plug 4
Master cylinder kit
1. Clean:
Master cylinder
Master cylinder kit
Clean them with brake fluid.
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)
2. Install:
Master cylinder cup (primary) 1
Master 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.
ÈFront
ÉRear
ÈÉ
È
É
3. Install:
Spring 1
To master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
ÈFront
ÉRear
È
É