Checking The Front Brake Calipers; Assembling The Front Brake Calipers - Yamaha 2012 TMAX XP500A Service Manual

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a. Blow compressed air into the brake hose
joint opening "a" to force out the pistons
from the brake caliper.
EWA13560
WARNING
• Cover the brake caliper pistons with a
rag. Be careful not to get injured when the
pistons are expelled from the brake cali-
per.
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts "4".
b. Remove the brake caliper piston dust seals
and brake caliper piston seals.
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EAS22391

CHECKING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
Recommended brake component replace-
ment schedule
Brake pads
Piston seals
Piston dust 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 cal-
iper 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.
EWA13611
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
EAS22411
ASSEMBLING THE FRONT BRAKE CALI-
PERS
EWA13621
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
4-45
FRONT BRAKE
If necessary
Every two years
Every two years
Every four years
Every two years and
whenever the brake is
disassembled