brake YAMAHA WR 400F 2000 Service Manual

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 - 18
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 - 19
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lBrake disc protector 1
lBolt (protector) 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 - 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 - 22
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 bolt.
3. Install:
lLocknut 1
lCirclip 2
NOTE:
lMake sure the circlip is installed into the
groove a of the push rod.
lAfter installing, check the brake lever posi-
tion. Refer to “FRONT BRAKE ADJUST-
MENT” section in the CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
New
EC5A5400
Rear master cylinder
1. Install:
lReservoir hose 1
lReservoir tank 2
2. Install:
lMaster cylinder 1
lBolt (master cylinder) 2

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
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..19 Nm (1.9 m · kg, 13 ft · lb)
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)

5 - 24
CHASFRONT BRAKE AND REAR BRAKE
3. Pass the brake hose through the cable
guide 1, then through the guide a on
the protector 2.
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.
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 on the end of
the brake hose with the tooth c on the cop-
per washer 1 and tighten the union bolt.
New
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)