Removing The Rear Brake Caliper; Disassembling The Rear Brake Caliper - Yamaha 2007 XP500 Service Manual

NOTE:
Align the projection "c" on the piston side of the
brake pad with the lower recess in the brake cal-
iper piston.
A
B
A. Up
B. Down
LLLLLLLLLLLLLLLLLLLLLL
5. Lubricate:
Rear brake caliper retaining bolts
G
Recommended lubricant
Lithium-soap-based grease
ECA15B1019
CAUTION:
Do not allow grease to contact the brake
G
pads.
Remove any excess grease.
G
6. Install:
Rear brake caliper retaining bolt
G
Rear brake caliper retaining bolt
27 Nm (2.7 m•kg, 20 ft•lb)
7. Install:
Rear brake caliper bracket bolts
G
Rear brake caliper bracket bolts
40 Nm (4.0 m•kg, 29 ft•lb)
8. Check:
Brake fluid level
G
Below the minimum level mark "a" → Add the
recommended brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-22.
c
4-41
9. Check:
Brake pedal operation
G
Soft or spongy feeling → Bleed the brake
system.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (XP500)" on page 3-24.
EAS22590

REMOVING THE REAR BRAKE CALIPER

NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
Nut "1"
G
Rear brake lock lever cable "2"
G
Pin "3"
G
Spring "4"
G
Union bolt "5"
G
Copper washers "6"
G
Brake hose "7"
G
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2
4
3
1
EAS22630
DISASSEMBLING THE REAR BRAKE
CALIPER
1. Remove:
Brake caliper piston "1"
G
Dust seal "2"
G
Brake caliper piston seal "3"
G
REAR BRAKE
7
5
6