Installing The Hydraulic Unit; Hydraulic Unit Operation Test - Yamaha 2007 XP500 Service Manual

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EAS22770c

INSTALLING THE HYDRAULIC UNIT

Proceed in the reverse order of disassembly.
Pay attention to the following items.
1. Install:
Hydraulic unit
G
Hydraulic unit bracket bolt
16 Nm (1.6 m•kg, 11 ft•lb)
NOTE:
When tightening the hydraulic unit nuts, first
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temporarily tighten the front nuts, and then
tighten the rear nut and the front nuts to speci-
fication in the order given.
Do not allow any foreign materials to enter the
G
hydraulic unit or the brake hoses when install-
ing the hydraulic unit.
ECA15B1021
CAUTION:
Do not remove the rubber plugs or bolts
(M10×1.25) installed in the union bolt holes
before installing the hydraulic unit.
NOTE:
Do not allow any foreign materials to enter the
hydraulic unit or the brake hoses when installing
the hydraulic unit.
2. Remove:
Rubber plugs or bolts (M10 × 1.25)
G
3. Install:
Copper washer
New
G
Brake hose "1" (to the rear brake caliper)
G
Brake hose "2" (from the rear brake master
G
cylinder)
Brake hose "3" (to the front brake caliper)
G
Brake hose "4" (from the front brake master
G
cylinder)
Union bolt
G
Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
ABS (Anti-Lock Brake System)
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EWA13940
WARNING
The brake hoses to the front and rear brake
calipers can be distinguished by the rubber
at the end of each hose. Be sure to connect
each brake hose to the correct union bolt
hole.
ECA14760
CAUTION:
To route the front and rear brake hoses, refer
to "CABLE ROUTING" on page 2-35.
4. Fill:
Brake master cylinder reservoir
G
Recommended brake fluid
DOT 4
5. Bleed the brake system.
6. Check the operation of the hydraulic unit ac-
cording to the brake lever and the brake ped-
al response. (Refer to "HYDRAULIC UNIT
OPERATION TEST" on page 4-49.)
ECA14770
CAUTION:
Always check the operation of the hydraulic
unit according to the brake lever and the
brake pedal response.
EAS22800

HYDRAULIC UNIT OPERATION TEST

The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested by the
following two methods.
Hydraulic unit operation test 1: this test gener-
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ates the same reaction-force pulsating action
that is generated in the brake levers when the
ABS is activated.
Hydraulic unit operation test 2: this test checks
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the function of the ABS after the system was
disassembled, adjusted, or serviced.
4-49
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