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• Brake caliper cylinder "2"
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body "3"
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
EWA17070
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
1
2. Check:
• Brake caliper bracket
Cracks/damage → Replace.
EAS30174
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA13621
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 seals and brake caliper piston
seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
Specified brake fluid
YAMAHA GENUINE BRAKE
FLUID (DOT 4)
EAS30175
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
3
2
4-43
1. Install:
• Front brake caliper "1"
(temporarily)
• Copper washers "2"
• Front brake hose "3"
• Brake hose union bolt "4"
Front brake hose union bolt
29 Nm (2.9 m·kgf, 21 ft·lbf)
EWA13530
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.
a
New
2
2. Remove:
• Front brake caliper
3. Install:
• Brake pad spring
• Brake pads
• Brake pad pin
• Speed sensor lead guide
• Front brake caliper
Front brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper bolt
35 Nm (3.5 m·kgf, 25 ft·lbf)
Refer to "REPLACING THE FRONT BRAKE
PADS" on page 4-41.
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
FRONT BRAKE
New
3
1
b
4
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