Checking The Rear Brake Caliper; Assembling The Rear Brake Caliper; Installing The Rear Brake Caliper - Yamaha TMAX 2020 Service Manual

EAS30188

CHECKING THE REAR BRAKE CALIPER

Recommended brake component replace-
ment schedule
Brake pads
Piston seal
Piston dust seal
Brake hoses
Brake fluid
1. Check:
• Brake caliper piston
Rust/scratches/wear  Replace the brake
caliper piston.
• Brake caliper cylinder
Scratches/wear  Replace the brake caliper
assembly.
• Brake caliper body
Cracks/damage  Replace the brake caliper
assembly.
• Brake fluid delivery passage
(brake caliper body)
Obstruction  Blow out with compressed air.
EWA13601
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
2. Check:
• Brake caliper bracket
Cracks/damage  Replace.
Refer to "REAR WHEEL" on page 4-30.
EAS30189

ASSEMBLING THE REAR BRAKE CALIPER

EWA17080
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 brake caliper
piston dust seal and brake caliper piston
seal to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
If necessary
Every two years
Every two years
Every four years
Every two years and
whenever the brake is
disassembled
Specified brake fluid
DOT 4
EAS30190

INSTALLING THE REAR BRAKE CALIPER

1. Install:
• Rear brake caliper "1"
(temporarily)
• Brake hose gasket
• Rear brake hose "2"
• Brake hose union bolt "3"
Rear brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
EWA13531
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA14170
NOTICE
When installing the brake hose onto the
brake caliper "1", make sure the brake pipe
"a" touches the projection "b" on the brake
caliper.
2. Remove:
• Rear brake caliper
3. Install:
• Brake pad support
• Rear brake pad
• Rear brake caliper
• Rear brake caliper bolt
Refer to "REPLACING THE REAR BRAKE
PADS" on page 4-58.
Rear brake caliper bolt
27 N·m (2.7 kgf·m, 20 lb·ft)
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
4-60
REAR BRAKE
New
2
a
b
3
1