Removing The Front Brake Caliper; Disassembling The Front Brake Caliper; Checking The Front Brake Caliper - Yamaha YZF-R15 Service Manual

REMOVING THE FRONT BRAKE CALIPER

NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
Brake hose union bolt
Copper washers
Brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
DISASSEMBLING THE FRONT BRAKE
CALIPER
1. Remove:
Brake caliper pistons "1"
Brake caliper piston seals"2"
Brake caliper dust seals"3"
1
s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s
a. Blow compressed air into the brake hose joint
opening "a" to force out the pistons from the
brake caliper.
WARNING
Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Never try to pry out the brake caliper pis-
ton.
a
1
2
3
2
4-20
b. Remove the brake caliper piston seals and
dust seals.
sssssssssssssssssssssssssssssssssssssss

CHECKING THE FRONT BRAKE CALIPER

Recommended brake component replace-
ment schedule
Brake pads
Piston seals
Dust seals
Brake hose
Brake fluid
1. Check:
Brake caliper pistons "1"
Rust/scratches/wear → Replace the brake
caliper pistons.
Brake caliper cylinders"2"
Scratches/wear → Replace the brake caliper
assembly.
Brake caliper body "3"
Cracks/damage → Replace the brake caliper
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals and dust seals.
2
1
2. Check:
Brake caliper bracket
Cracks/damage → Replace.
FRONT BRAKE
If necessary
Every two years
Every two years
Every four years
Every two years and
whenever the brake
is disassembled
3
2