Assembling The Front Brake Caliper; Installing The Front Brake Caliper - Yamaha YZF-R15 Service Manual

ASSEMBLING THE FRONT BRAKE CALIPER

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 piston seals
and dust seals to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals and
dust seals.
Recommended fluid
DOT 3 or DOT

INSTALLING THE FRONT BRAKE CALIPER

1. Install:
Brake caliper
(temporarily)
New
Copper washers
Brake hose
Brake hose union bolt
Brake hose union bolt
26 Nm (2.6 m·kg, 19 ft·lb)
CAUTION:
When installing the brake hose onto the
brake caliper "1", make sure the brake pipe
"a" touches the projection "b" on the brake
caliper.
a
2. Remove:
Brake caliper
4
b
1
4-21
3. Install:
Brake pad spring
Brake pads
Brake caliper
Brake hose holder
Brake caliper bolt
35 Nm (3.5 m·kg, 25 ft·lb)
Brake hose holder
7 Nm (0.7 m·kg, 5.1 ft·lb)
Refer to "REPLACING THE FRONT BRAKE
PADS" on page 4-20.
4. Fill:
Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 3 or DOT
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.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts.Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-18.
6. Check:
Brake fluid level
Below the minimum level mark "a" → Add the
recommended brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-17.
FRONT BRAKE
4