brake YAMAHA WR 400F 2001 Owner's Guide

ENG
4 - 88
ENGINE REMOVAL
Extent of removal:1 Engine removal
Extent of removal Order Part name Q’ty Remarks
1 Engine skidplate 1
2 Neutral switch 1
3 Oil hose 2
4 Chain cover 1
Refer to “REMOVAL POINTS”. 5 Nut (drive sprocket) 1
6 Lock washer 1
7 Drive sprocket 1
8 Clip 1
9 Bolt (brake pedal) 1
10 Brake pedal 1
11 Engine upper bracket (right) 1
12 Engine upper bracket (left) 1
13 Engine lower bracket 2
14 Engine mounting bolt 3
15 Pivot shaft 1
Refer to “REMOVAL POINTS”.
16 Engine 1
1

4 - 89
ENGENGINE REMOVAL
EC4M3000
REMOVAL POINTS
EC4F3100
Drive sprocket
1. Remove:
lNut (drive sprocket) 1
lLock washer 2
NOTE:
lStraighten the lock washer tab.
lLoosen the nut while applying the rear brake.
2. Remove:
lDrive sprocket 1
lDrive chain 2
NOTE:
Remove the drive sprocket together with the
drive chain.
EC4M3301
Engine removal
1. Remove:
lPivot shaft 1
NOTE:
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:
lEngine 1
From right side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.

4 - 90
ENGENGINE REMOVAL
EC4M5000
ASSEMBLY AND INSTALLATION
EC4M5160
Engine installation
1. Install:
lEngine 1
Install the engine from right side.
lPivot shaft 2
lEngine mounting bolt (lower) 3
lEngine lower bracket 4
lBolt (engine bracket) 5
lEngine mounting bolt (front) 6
lEngine upper bracket (right) 7
lEngine upper bracket (left) 8
lBolt (engine bracket) 9
lEngine mounting bolt (upper) 0
EC4M5211
Brake pedal
1. Install:
lSpring
lBrake pedal 1
lO-ring 2
lBolt (brake pedal) 3
lClip 4
NOTE:
lApply the lithium soap base grease on the
bolt, O-rings and brake pedal bracket.
lInstall the clip with its stopper portion a fac-
ing inward.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
T R..69 Nm (6.9 m · kg, 50 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..69 Nm (6.9 m · kg, 50 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
EC4M5331
Drive sprocket
1. Install:
lDrive sprocket 1
lDrive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.

4 - 91
ENGENGINE REMOVAL
2. Install:
lLock washer 1
lNut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
3. Bend the lock washer tab to lock the nut.
4. Install:
lChain guide
lChain cover 1
lScrew (chain cover) 2
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
5. Install:
lOil hose 1
lBolt (oil hose) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
6. Install:
lSpring 1
lPin 2
lO-ring 3
lNeutral switch 4
lBolt (neutral switch) 5
NOTE:
Apply the lithium soap base grease on the O-
ring.
New
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

5 - 1
CHAS

EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Break disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Trip meter cable 1
2 Hose cover 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Bolt (axle holder) 4 Only loosening.
5 Nut (front wheel axle) 1
6 Front wheel axle 1
7 Front wheel 1
8 Trip meter gear unit 1
9 Collar 1
10 Oil seal 1
11 Bearing 2 Refer to “REMOVAL POINTS”.
12 Brake disc 1
2
31
3

FRONT WHEEL AND REAR WHEEL




5

5 - 2
CHAS

EC598100
REAR WHEEL
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
REAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3

FRONT WHEEL AND REAR WHEEL

5 - 4
CHAS

FRONT WHEEL AND REAR WHEEL
EC514200
Wheel axle
1. Measure:
l
Wheel axle bends
Out of specification
®
Replace.
Use the dial gauge
1
.
NOTE:

The bending value is shown by one half of the
dial gauge reading.
WARNING

Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)
EC594200
Brake disc
1. Measure:
l
Brake disc deflection (only rear brake
disc)
Use the dial gauge
1
.
Out of specification
®
Inspect wheel
runout.
If wheel runout is in good condition,
replace the brake disc.
2. Measure:
l
Brake disc thickness
a

Out of limit
®
Replace.
Disc deflection limit:
Standard
Rear —0.15 mm
(0.006 in)
Disc wear limit:
Standard
Front3.0 mm
(0.12 in)2.5 mm
(0.10 in)
Rear4.0 mm
(0.16 in)3.5 mm
(0.14 in)

5 - 5
CHAS

FRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
l
Bearing (left)
1

l
Spacer
2

l
Bearing (right)
3

l
Oil seal
4

NOTE:

l
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
l
Use a socket that matches the outside diam-
eter of the race of the bearing.
l
Left side of bearing shall be installed first.
l
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
lBrake disc 1
lBolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lInstall the collar with their projection a fac-
ing the wheel.
4. Install:
lTrip meter gear unit 1
NOTE:
Make sure the two projections a in the wheel
hub are meshed with the two slots b in the trip
meter gear unit.b a1

5 - 6
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
lWheel
NOTE:
lInstall the brake disc between the brake
pads correctly.
lMake sure that the projections a in the trip
meter gear unit fits over the stopper b on
the front fork outer tube.
6. Install:
lWheel axle 1
NOTE:
Apply the lithium soap base grease on the
wheel axle.
7. Install:
lNut (wheel axle) 1
T R..105 Nm (10.5 m · kg, 75 ft · lb)
8. Tighten:
lBolt (axle holder) 1
NOTE:
Before tightening the bolt, fit the wheel axle to
the axle holder by stroking the front fork sev-
eral times with the front brake applied.
T R..23 Nm (2.3 m · kg, 17 ft · lb)

5 - 7
CHASFRONT WHEEL AND REAR WHEEL
9. 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).
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
10. Install:
lHose cover 1
lPlain washer 2
lBolt [hose cover (M8)] 3
lBolt [hose cover (M6)] 4
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
11. Install:
lTrip meter cable 11