Installing The Front Brake Calipers; Checking The Front Brake Master Cylinder - Yamaha Grizzly550 User Manual

• Whenever a brake caliper is disassembled,
replace the brake caliper piston seal and
dust seal.
Recommended fluid
DOT 4
EAS22440

INSTALLING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
1. Install:
• Brake caliper assembly
• Brake caliper bolts "1"
• Brake hose "2"
• Copper washers "3"
• Brake hose union bolt "4"
Brake caliper bolt
30 Nm (3.0 m·kg, 22 ft·lb)
Brake hose union bolt
27 Nm (2.7 m·kg, 19 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-33.
ECA28P1014
NOTICE
When installing the brake hose onto the
brake caliper, make sure the brake pipe
touches the projection "a" on the brake cali-
per.
2
4
2. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 4
New
1
a
3
New
1
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-23.
4. Check:
• Brake fluid level
Below the minimum level mark → Add the
recommended brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-21.
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-23.
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace.
• Brake master cylinder reservoir diaphragm
Cracks/damage → Replace.
4-29
FRONT BRAKE