Assembling The Front Brake Calipers; Installing The Front Brake Calipers - Yamaha 2007 XP500 Service Manual

2. Check:
Brake caliper brackets "1"
G
Cracks/damage → Replace.
1
EAS22410
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA13620
WARNING
Before installation, all internal brake com-
G
ponents should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake com-
G
ponents as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
G
replace the brake caliper piston seals.
Recommended fluid
DOT 4
1. Install:
Brake caliper piston seal "1"
G
Dust seal "2"
New
G
Brake caliper piston "3"
G
New
4-30
2. Install:
Brake caliper bracket
G
Brake caliper bracket bolt
40 Nm (4.0 m•kg, 29 ft•lb)
EAS22440

INSTALLING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
1. Install:
Brake caliper "1"
G
(temporarily)
Copper washers New
G
Brake hose "2"
G
Union bolt "3"
G
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-35.
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper "1", make sure the brake pipe
"a" touches the projection "b" on the brake
caliper.
2. Remove:
Brake caliper
G
FRONT BRAKE
2
1
a
3