Introduction; Checking The Front Brake Discs - Yamaha 2009 XP500Y TMAX Service Manual

EAS22220

INTRODUCTION

EWA4B51008
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
• Never use solvents on internal brake com-
ponents.
• Use only clean or new brake fluid for clean-
ing brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID GETTING
INTO THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240

CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
1. Remove:
• Front wheel
Refer to "FRONT WHEEL" on page 4-8.
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
0.15 mm (0.0059 in)
M MMM M MMM M M MMM M M MMM M
a. Place the vehicle on a suitable stand so that
the front wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
M MMM M M MMM M MMM
4-23
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
L LLL L LLL L L LLL L L LLL L
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
Brake disc thickness limit
3.5 mm (0.14 in)
5. Adjust:
• Brake disc deflection
M MMM M MMM M M MMM M M MMM M
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc and new brake disc
bolts.
Front brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
FRONT BRAKE
L LLL L L LLL L LLL
M MMM M M MMM M MMM