Installing The Front Brake Calipers - Yamaha XT1200Z(Z) 2010 Service Manual

• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and 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
(temporarily)
• Brake hose gaskets
• Brake hose (hydraulic unit to left front brake
caliper) "1"
• Brake hose (left front brake caliper to right
front brake caliper) "2"
• Brake hose union bolt "3"
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-43.
ECA23P1020
NOTICE
Left side
• When installing the brake hose "1" onto the
brake caliper, make sure that the brake pipe
"a" contacts the projection "b" on the
brake caliper.
• When installing the brake hose "2" onto the
brake caliper, make sure that the projection
"c" on the brake hose "2" contacts the pro-
jection "d" on the brake hose "1".
Right side
• When installing the brake hose "2" onto the
brake caliper, make sure that the paint mark
"e" on the brake hose "2" faces outward
and that the brake pipe "f" contacts the pro-
jection "g" on the brake caliper.
New
A
a
d
B
2
e
f
A. Left side
B. Right side
2. Remove:
• Front brake caliper
3. Install:
• Brake pads
• Brake pad spring
• Brake pad pin
• Brake pad clips
• Front brake caliper
Refer to "REPLACING THE FRONT BRAKE
PADS" on page 4-45.
Front brake caliper bolt
40 Nm (4.0 m·kgf, 29 ft·lbf)
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 4
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
4-48
FRONT BRAKE
1
c
g
2
b
3
3