Inspection And Repair - Yamaha SZR 660 Service Manual

FRONT AND REAR BRAKE
INSPECTION
AND
REPAIR
Recommended
programme
for the
replacement
of
brake system components:
Pads
When
necessary
Sealing elements,
rear caliper
dust
cover
Every
2
years
Front
and
rear master
cylinder unit, front caliper
In the
event
of
brake
fluid
leakage
Brake hoses Every
4 years
Brake
fluid
Replace
only after
disassembling brake
WARNING
Internal parts
must
be
washed
only with clean
brake
fluid.
Do
not
use
solvents to prevent
sealing elements from
becoming misshapen
or
swollen.
1.
Replace caliper
(A}
[BI
2.
Inspect:
•
Caliper pistons
(1)
Rust/Wear/Damage
-
assembly,
•
Caliper cylinder
(2)
Scratching/Wear -> Replace
caliper as-
sembly.
Front
Rear
Inspect:
•
Caliper body
(3)
Cracks/Damage -»
Replace.
•
Guide pin
(4)
Rust/Damage
-> Repface,
• Lock
spring
(5)
Rust/Damage ~»
Replace.
• Dust
seals
(6)
Cracks/Wear/Damage
-* Repface.
•
Oil delivery
passages
(caliper body)
Clean with
compressed
air.
WARNING
Replace the piston sealing element and dust
seals every time the caliper
is
disassembled.
FRONT
AND
REAR BRAKE
B
3. Inspect:
• Master cylinder
(1)
Wear/Scratches ** Replace master
cylin-
der
unit.
• Master cylinder
body
(2)
Cracks/Damage
-» Replace.
•
Oi! feed
passage (main
cylinder)
Clean
with a
jet
of
compressed
air.
[A] Front
[B]
Rear
Inspect:
• Master
cylinder piston unit
(3)
Scratches/Wear/Damage
^
Replace mas-
ter cylinder
unit.
Inspect:
• Tank diaphragm
(4)
Wear/Damage
-* Replace.
•
Tank
(5)
Cracks/Damage
->
Replace.
Inspect:
•
Brake hoses
(6)
•
Tank hose
(7)
Cracks/Wear/Damage
-» Replace.
7-25 7-26