Assembling The Rear Brake Master Cylinder; Installing The Rear Brake Master Cylinder - Yamaha 2007 XP500 Service Manual

4. Check:
Brake hoses
G
Cracks/damage/wear → Replace.
EAS22730
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
EWA13520
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.
Recommended fluid
DOT 4
1. Install:
Master cylinder kit "1"
G
Circlip "2"
New
G
Dust boot "3"
G
Cylinder cup installer
90890-01996
EAS22750
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
Brake master cylinder "1"
G
Brake master cylinder holder "2"
G
Holder bolts
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Install the brake master cylinder holder with the
G
"UP" mark facing up "a".
Align the brake master cylinder with the projec-
G
tion "b" on the handlebar.
First, tighten the upper bolt, then the lower bolt.
G
a
2
2. Install:
Copper washers "1"
G
Brake hoses "2"
G
Union bolt "3"
G
Brake hose 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 "CABLE
ROUTING" on page 2-35.
NOTE:
While holding the brake hose, tighten the union
G
bolt as shown.
Turn the handlebar to the left and to the right to
G
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
ECA14160
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection "a" as shown.
4-45
REAR BRAKE
1
b
New