Checking The Front Brake Calipers; Assembling The Front Brake Calipers; Installing The Front Brake Calipers - Yamaha FJR1300A(D) Service Manual

EWA13560
WARNING
• Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper piston dust seals
and brake caliper piston seals.
▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲
EAS22390

CHECKING THE FRONT BRAKE CALIPERS

Recommended brake component replace-
ment schedule
Brake pads
Piston dust seals
Piston 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 caliper
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.
EWA3P6D001
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
1
▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲
If necessary
Every two years
Every two years
Every four years
Every two years and
whenever the brake
is disassembled
3
2
1
EAS22410
ASSEMBLING THE FRONT BRAKE
CALIPERS
EWA3P6D002
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
▲▲▲
seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
EAS22440

INSTALLING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
1. Install:
• Front brake caliper "1"
(temporarily)
• Copper washers
• Brake hose (brake pipe/upper joint assembly
to right front brake caliper) "2"
• Brake hose (metering valve to right front
brake caliper) "3"
• Brake hose union bolts "4"
EWA1MC1014
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-47.
ECA14170
NOTICE
When installing the brake hose onto the
brake caliper "1", make sure the brake pipe
"a" touches the projection "b" on the brake
caliper.
4-46
FRONT BRAKE
Specified brake fluid
DOT 4
New
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)