Checking The Front Brake Calipers; Assembling The Front Brake Calipers; Installing The Front Brake Calipers - Yamaha XV19SW Service Manual

b. Remove the brake caliper piston seals.
L LLL L LLL L L LLL L L LLL L
EAS22390

CHECKING THE FRONT BRAKE CALIPERS

Recommended brake component replace-
ment schedule
Brake pads
Piston seals
Brake hoses
Brake fluid
1. Check:
• Brake caliper pistons "1"
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders "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.
EWA13600
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
3
1
1
a
L LLL L L LLL L LLL
If necessary
Every two years
Every four years
Every two years and
whenever the brake
is disassembled
2
4-39
FRONT BRAKE
EAS22410
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA13620
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 piston seals
to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended fluid
DOT 4
EAS22440

INSTALLING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
1. Install:
• Front brake caliper "1"
(temporarily)
• Copper washers New
• Front brake hose "2"
• Front brake hose union bolt "3"
Front brake hose union bolt
32 Nm (3.2 m·kg, 23 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-45.
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
3
1
2
b