Disassembling The Front Brake Calipers; Checking The Front Brake Calipers - Yamaha 2007 XP500 Service Manual

brake calipers.
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
Union bolt "1"
G
Copper washers "2"
G
Brake hose
G
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS22350
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
Brake caliper pistons "1"
G
Dust seals "2"
G
Brake caliper piston seals "3"
G
MMMMMMMMMMMMMMMMMMMMMM
a. Blow compressed air into the brake hose joint
opening "a" to force out the piston from the
brake caliper.
EWA13580
WARNING
Cover the brake caliper piston with a rag.
G
Be careful not to get injured when the pis-
ton is expelled from the brake master cylin-
der.
Never try to pry out the brake caliper pis-
G
ton.
b. Remove the brake caliper piston seals.
2
LLLLLLLLLLLLLLLLLLLLLL
1
EAS22390

CHECKING THE FRONT BRAKE CALIPERS

Recommended brake component replacement
Brake pads
Piston seals
Brake hoses
Brake fluid
1. Check:
Brake caliper pistons "1"
G
Rust/scratches/wear → Replace the brake
caliper pistons.
Brake caliper cylinders "2"
G
Scratches/wear → Replace the brake caliper
assembly.
Brake caliper body "3"
G
Cracks/damage → Replace the brake caliper
assembly.
Brake fluid delivery passages
G
(brake caliper body)
Obstruction → Blow out with compressed air.
EWA13600
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
4-29
FRONT BRAKE
a
schedule
If necessary
Every two years
Every four years
Every two years and
whenever the brake is
disassembled