brake YAMAHA WR 426F 2001 Manuale duso (in Italian)

5 - 19
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 - 20
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
lDisc cover 1
lBolt (disc cover) 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 - 21
CHASFRONT BRAKE AND REAR BRAKE
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 dia. side.
Front
õRear
õ

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
lMaster cylinder kit 1
lPlain washer 2
lCirclip 3
lMaster cylinder boot 4
To master cylinder 5.
[Rear]
lMaster cylinder kit 1
lPush rod 2
lCirclip 3
lMaster cylinder boot 4
To master cylinder 5.
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
EC5A5310
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 - 23
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
brake lever sliding surface, bolt and contacting
surface of the master cylinder piston.
Rear master cylinder
1. Install:
lReservoir hose 1
lReservoir tank 2
lBolt (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:
lMaster cylinder 1
lBolt (master cylinder) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
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..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 24
CHASFRONT BRAKE AND REAR BRAKE
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)
3. Pass the brake hose through the cable
guide 1, then through the guide a on
the protector 2.

5 - 25
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
lCopper washer 1
lBrake hose 2
lUnion bolt 3
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 master cylinder.
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 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:
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)
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 - 27
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
lScrew (reservoir tank cap) 2
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)
lProtector 1
lBolt (protector) 2

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)
õ
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

5 - 28
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (handle crown) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (under bracket) 2 Only loosening.
6 Front fork 1
1