Assembling The Rear Brake Caliper; Installing The Rear Brake Caliper - Yamaha 2009 XP500Y TMAX Service Manual

EAS22660

ASSEMBLING THE REAR BRAKE CALIPER

EWA4B51010
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper
piston dust seal and piston seal to swell
and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and piston seal.
Recommended fluid
DOT 4
1. Install:
• Brake caliper piston "1"
Turn the brake caliper piston clockwise until
section "a" of the brake caliper piston is level
with the surface of the brake caliper body.
TIP
Align the recesses "b" in the brake caliper piston
with the brake caliper body as shown in the illus-
tration.
1
a
EAS22670

INSTALLING THE REAR BRAKE CALIPER

1. Install:
• Rear brake caliper bracket
• Rear brake caliper "1"
(temporarily)
• Brake hose gaskets
• Rear brake hose "2"
• Brake hose union bolt "3"
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-35.
ECA14170
NOTICE
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
1
2. Remove:
• Rear brake caliper retaining bolt (rear)
• Rear brake caliper
• Rear brake caliper bracket
3. Install:
• Brake pad supports
• Rear brake pads
• Rear brake caliper bracket
• Rear brake caliper
• Rear brake caliper retaining bolt (rear)
Refer to "REPLACING THE REAR BRAKE
PADS" on page 4-36.
b
4-40
REAR BRAKE
New
Rear brake caliper retaining bolt
(front)
31 Nm (3.1 m·kg, 22 ft·lb)
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
b
a
3
Rear brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
Rear brake caliper retaining bolt
(rear)
31 Nm (3.1 m·kg, 22 ft·lb)
1