brake fluid YAMAHA WR 400F 2000 User Guide

5 - 15
CHASFRONT BRAKE AND REAR BRAKE
EC533402
Piston seal kit
1. Remove:
lDust seal 1
lPiston 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.
Front
õRear

õ
EC5A4000
INSPECTION
EC534112
Master cylinder
1. Inspect:
lMaster cylinder inner surface a
Wear/scratches ® Replace master cyl-
inder assembly.
Stains ® Clean.
WARNING
Use only new brake fluid.
Front
õRear
2. Inspect:
lDiaphragm 1
Crack/damage ® Replace.
Front
õRear
õ
õ
3. Inspect:
lMaster cylinder piston 1
lMaster cylinder cup 2
Wear/damage/score marks ® Replace
master cylinder kit.
Front
õRear
õ

5 - 16
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 - 17
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 - 20
CHASFRONT BRAKE AND REAR BRAKE
EC5A5200
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 diameter side.
Front
õRear
õ

5 - 21
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
lMaster cylinder kit 1
lPush rod 2
lPlain washer 3
lCirclip 4
lMaster cylinder boot 5
lLocknut 6
To master cylinder 7.
[Rear]
lMaster cylinder kit 1
lPush rod 2
lCirclip 3
lMaster cylinder boot 4
lLocknut 5
To master cylinder 4.
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
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 - 25
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)
EC5A5600
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 - 26
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
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)
lCaliper protector 1
lBolt (protector) 2

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)