Brake Calipers - Removal, Overhaul And Installation - Yamaha TDM850 User Manual

7*6 Brakes, wheels and tyres
2.11c Slide the caliper onto the disc .
then fit the inner pad, locating the cutout against
the guide (see illustration 2.2d). Install the pad
pins, making sure they pass through the hole in
each pad, and tighten them finger-tight (see
illustration 2.2c). Install the brake caliper and
tighten its bolts to the torque setting specified at
the beginning of the Chapter, then tighten the
pad retaining pins to the specified torque (see
illustrations).
12 Top up the master cylinder reservoir if
necessary (see Daily (pre-ride) checks), and refit
the reservoir cover and diaphragm.
3.1 Unscrew the bolts (arrowed) and
remove the shield
3.2a Unscrew the brake hose banjo bolt (arrowed), noting its
alignment
2.11d .. and tighten the mounting
bolts ...
13 Operate the brake lever several times to bring
the pads into contact with the disc. Check the
operation of the brake before riding the
motorcycle.
Brake calipers - removal,
overhaul and installation
A Warning: If a caliper
indicates the need for an overhaul
(usually due to leaking fluid or sticky
operation), all old brake fluid should
be flushed from the system. Also, the dust
created by the brake system may contain
asbestos, which is harmful to your health.
Never blow it out with compressed air and
don't inhale any of it. An approved filtering
mask should be worn when working on the
brakes. Do not, under any circumstances, use
petroleum-based solvents to clean brake parts.
Use clean brake fluid only on the internal
parts. Brake cleaner or denatured alcohol can
be used on external parts.
Removal
1 On XTZ models, if removing the rear brake
caliper, unscrew the bolts securing the rear
3.2b Counter-hold the hose nut (A) and unscrew the locknut (B)
2.11e ... and the pad pins to the specified
torque
caliper shield and remove the shield (see
illustration). If the brake pads are being
removed from the calipers, slacken the pad
retaining pins now (see illustration 2.2a).
2 If the calipers are just being displaced and not
I
completely removed or overhauled, do not
disconnect the brake hose. If the calipers are
being overhauled, unscrew the brake hose banjo
bolt (see illustration). Note the alignment of the
hose on the caliper and separate the hose from
the caliper. On the rear caliper on TDM models,
counter-hold the hose nut and unscrew the
locknut and separate the hose from the hose joint
in the caliper (see illustration). Plug the hose
end or wrap a plastic bag tightly around it to
minimise fluid loss and prevent dirt entering the
system. Discard the banjo bolt sealing washers
as new ones must be used on installation. Note:
If you are planning to overhaul the caliper and
don't have a source of compressed air to blow
out the pistons, just loosen the banjo bolt at this
stage and retighten it lightly. The bike's hydraulic
system can then be used to force the pistons out
of the body once the pads have been removed.
Disconnect the hose once the pistons have been
sufficiently displaced.
3 Unscrew the caliper mounting bolts, and
from the hose joint (C)
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