Assembling The Front Brake Caliper; Installing The Front Brake Caliper - Yamaha XT250X Service Manual

1. Check:
Brake caliper pistons "1"
G
Rust/scratches/wear → Replace the brake
caliper pistons.
Brake caliper cylinders "2"
G
Scratches/wear → Replace the brake caliper
assembly.
Brake caliper body "3"
G
Cracks/damage → Replace the brake caliper
assembly.
Brake fluid delivery passages
G
(brake caliper body)
Obstruction → Blow out with compressed air.
2
EWA13610
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
2. Check:
Brake caliper bracket
G
Cracks/damage → Replace.
EAS22400

ASSEMBLING THE FRONT BRAKE CALIPER

EWA13620
WARNING
Before installation, all internal brake com-
G
ponents should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake com-
G
ponents as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
G
replace the brake caliper piston seals.
Recommended fluid
DOT 4
EAS22420

INSTALLING THE FRONT BRAKE CALIPER

1. Install:
Front brake caliper bracket
G
Front brake caliper
G
(temporarily)
3
1
Copper washers
G
Front brake hose
G
Union bolt
G
Front brake caliper bracket bolt
40 Nm (4.0 m•kg, 29 ft•lb)
Union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CA-
BLE ROUTING" on page 2-25.
ECA14170
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
1
2. Remove:
Front brake caliper
G
3. Install:
Brake pad springs
G
Front brake pad
G
Front brake caliper
G
Brake caliper support bolt
G
Refer to "REPLACING THE FRONT BRAKE
PADS" on page 4-18.
Brake caliper support bolt
32 Nm (3.2 m•kg, 23 ft•lb)
4. Fill:
Brake master cylinder reservoir
G
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 4
EWA13090
WARNING
Use only the designated brake fluid. Other
G
4-20
FRONT BRAKE
New
b