Hydraulic Brake Pad Replacement - Yamaha MM700A Manual

HYDRAULIC BRAKE PAD REPLACEMENT

There is no recommended time interval for changing
the brake pads on the main brake. Pad wear depends
greatly on riding habits and conditions. Always replace
both pads in the caliper at the same time.
The brake pads on the parking brake are not renewable;
replace the brake caliper lever arms if the pads are exces-
sively worn.
Refer to Figure 1 for this procedure. The brake caliper
(Figure 2) is mounted on the chaincase.
NOTE
It is not necessary to disconnect the brake
hose from the brake when replacing the
brake pads.
1.
Open and secure the shroud.
NOTE
Do not operate the brake lever after remov-
ing the brake caliper in Step 3. Operating
the brake lever forces the piston out of the
caliper. Place a piece of wood between the
seating from the accidental use o f the brake
lever.
3. Lift the brake calipcr assembly off the brake disc.
4. Clean any debris off the caliper assembly.
5. Unscrew the retaining pin lockscrew (Figure 4), then
unscrew the brake pad retaining pin behind the lockscrew.
6. Remove the pad spring, brake pads and shims (Figure
cracks or excessive wear. Minimum allowable brake pad
thickness (Figure 6) is 4.2 mrn (0.17 in.). Replace both
brake pads as a set.
8. When new brake pads are installed in the caliper the
master cylinder brake fluid will rise as the calipcr pistons
are repositioned. Clean the top of the master cylinder of
all dirt. Remove the cover (Figure 7) and diaphragm from
the master cylinder and slowly push each caliper piston
(Figure 8) into the calipcr. Constantly check the reservoir
to make sure brake fluid does not overflow. Remove the
fluid, if necessary, before it overflows. The piston should
move freely in the caliper bore. If the piston does not
move smoothly and it is sticking in the caliper, remove the
caliper as described in Caliper Overhaul in this chapter.
9. Install brake pads as follows:
a. Assemble each brake pad with the shims as shown
in Figure 1. Note that the tabs on the outer shim fit
over the inner shim and brake pad (Figure 9).
the friction surface on both pads face each other.
c. Install the pad retaining spring plate (Figure 10) so
the tabs fit into the recesses in the caliper.
d. Install the brake pad retaining pin and the retaining
pin lockscrew (Figure 4).
10. Place the brake caliper assembly over the brake disc
so a brake pad is located on each side of the disc. Do not
force the brake caliper over the disc in order to not dam-
age the brake pads. If the caliper is difficult to install, the
piston needs to be pushed farther into the caliper bore.
11. Install the caliper retaining screws and tighten to 48
12. Actuate the brake lever as many times as needed to
refill the cylinder in the caliper and correctly position the
pads.
13. Refill the master cylinder reservoir, if necessary, to
maintain the correct brake fluid level. Install the dia-
phragm and top cover.
fluid
Use brake from a sealed container
brakes). Other types may vaporize and
cause brake failure. Do not intermix differ-
ent brands or types as they may not
patible. Do not intermix a silicone hased
5) brake fluid
(DOT
component damage leading to brake system
failure.
Do not operate the snowmobile until the
brake i s operating correctly with full hy-
draulic advantage. I f necessary, bleed the
brake system as described in this chapter.
BRAKE CALlPER
1. Open and secure the shroud.
NOTE
other components, hut caliper service is not
required, it may be possible to relocate the
caliper without disconnecting the brake
hose from the caliper. DO NOT allow the
caliper to hang/rom the brake hose.
NOTE
Be prepared to catch brake fluid when dis-
connecting the brake hose.
com-
as it can cause brake