brake YAMAHA WR 400F 2002 Workshop Manual

5 - 18
CHAS
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.
ÅFront
ıRear
Å
New
New
ı
FRONT BRAKE AND REAR BRAKE
3. Install:
Caliper piston 1
NOTE:
Apply the brake fluid on the piston wall.
CAUTION:
For 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.
Never force to insert.
ÅFront
ıRear
EC5A5700
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.
Å
ı

5 - 19
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Copper washer 1
Union 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:
Brake hose holder 1
Caliper 2
Bolt (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:
Pad pin 4
5. Install:
Pad 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:
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.

5 - 20
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Disc cover 1
Bolt (disc cover) 2
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Copper washer 1
Brake hose 2
Union 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:
Caliper 1
Rear wheel 2
Refer to “FRONT WHEEL AND REAR
WHEEL” section.
5. Tighten:
Pad pin 3
6. Install:
Pad 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 - 21
CHASFRONT BRAKE AND REAR BRAKE
Master cylinder kit
1. Clean:
Master cylinder
Master cylinder kit
Clean them with brake fluid.
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.
ÅFront
ıRear
Åı
Åı
3. Install:
Spring 1
To master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
ÅFront
ıRear
Åı

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
Master cylinder kit 1
Plain washer 2
Circlip 3
Master cylinder boot 4
To master cylinder 5.
[Rear]
Master cylinder kit 1
Push rod 2
Circlip 3
Master cylinder boot 4
To master cylinder 5.
NOTE:
Apply the brake fluid on the master cylinder
kit.
Apply the lithium soap base grease on the tip
of the push rod.
When installing the circlip, use a long nose
circlip pliers.
ÅFront
ıRear
Å
ı
EC5A5310
Front master cylinder
1. Install:
Master cylinder 1
Master cylinder bracket 2
Bolt (master cylinder bracket) 3
NOTE:
Install the bracket so that the arrow mark a
face upward.
First 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 - 23
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake lever 1
Bolt (brake lever) 2
Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the master cylinder piston.
Rear master cylinder
1. Install:
Reservoir hose 1
Reservoir tank 2
Bolt (reservoir tank) 3
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
Master cylinder 1
Bolt (master cylinder) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Spring 1
Brake pedal 2
O-ring 3
Bolt (brake pedal) 4
Clip 5
NOTE:
Apply the lithium soap base grease on the
bolt, O-ring and brake pedal bracket.
Install the clip with its stopper portion a fac-
ing inward.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 24
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Pin 1
Plain washer 2
Cotter 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:
Brake 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:
Hose cover 1
Plain washer 2
Bolt [hose cover (M8)] 3
Bolt [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)
3. Pass the brake hose through the cable
guide 1, then through the guide a on
the protector 2.

5 - 25
CHAS

FRONT BRAKE AND REAR BRAKE
4. Install:

Copper washer
1


Brake hose
2


Union 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:

Copper washer
1


Brake hose
2


Copper washer
3

Union 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:
Brake hose holder 1
Screw (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..1 Nm (0.1 m · kg, 0.7 ft · lb)
Brake fluid
1. Fill:
Brake fluid
Until the fluid level reaches “LOWER”
level line a.
WARNING
Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid;
mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
Be 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.
ÅFront
ıRear
Recommended brake fluid:
DOT #4
Å
ı

5 - 27
CHASFRONT BRAKE AND REAR BRAKE
2. Air bleed:
Brake system
Refer to “BRAKE SYSTEM AIR
BLEEDING” section in the CHAPTER
3.
3. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
Refer to “BRAKE FLUID LEVEL
INSPECTION” section in the CHAP-
TER 3.
4. Install:
[Front]
Diaphragm
Master cylinder cap 1
Screw (master cylinder cap) 2
[Rear]
Diaphragm
Reservoir tank cap 1
Screw (reservoir tank cap) 2
Master 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.
ÅFront
ıRear
5. Install: (rear brake only)
Protector 1
Bolt (protector) 2
Å
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)
ı
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)