Introduction; Checking The Front Brake Disc; Removing The Front Brake Caliper; Disassembling The Front Brake Caliper - Yamaha WR250F 2016 Owner's Service Manual

INTRODUCTION

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EWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components
unless absolutely necessary.
• If there is any problem with connections
on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing brake
components.
• Use new brake fluid for cleaning the brake
components.
• Immediately wipe off the spilled brake fluid
to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to
let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.

CHECKING THE FRONT BRAKE DISC

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1. Remove:
• Front wheel
Refer to "FRONT WHEEL" on page 5-4.
2. Check:
• Front brake disc
Damage/galling  Replace.
3. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace.
Brake disc thickness limit
2.5 mm (0.10 in)
4. Install:
• Front wheel
Refer to "FRONT WHEEL" on page 5-4.

REMOVING THE FRONT BRAKE CALIPER

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TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid.
DISASSEMBLING THE FRONT BRAKE CAL-
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IPER
1. Remove:
• Brake caliper piston "1"
• Brake caliper piston dust seal "2"
• Brake caliper piston seals "3"
1
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a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA
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.
5-17
FRONT BRAKE
3
2