Checking The Rear Brake Caliper; Assembling The Rear Brake Caliper; Installing The Rear Brake Caliper - Yamaha 2009 Diversion XJ6S Service Manual

Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Never try to pry out the brake caliper pis-
G
ton.
c. Remove the brake caliper piston dust seal
and brake caliper piston seal.
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL
EAS22640

CHECKING THE REAR BRAKE CALIPER

Recommended brake component
replacement schedule
Brake pads
Piston seals
Brake hoses
Brake fluid
1. Check:
Brake caliper piston "1"
G
Rust/scratches/wear → Replace the brake
caliper pistons.
Brake caliper cylinder "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.
b
a
If necessary
Every two years
Every four years
Every two years and
whenever the brake is dis-
assembled
EWA13610
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
2. Check:
Rear brake caliper bracket "1"
G
Cracks/damage → Replace.
EAS22650

ASSEMBLING THE REAR BRAKE CALIPER

EWA13620
WARNING
Before installation, all internal brake com-
G
ponents should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake com-
G
ponents as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
G
replace the brake caliper piston seals.
Recommended fluid
DOT 4
1. Install:
Brake caliper piston seal
G
Brake caliper piston dust seal
G
Brake caliper piston
G
EAS22670

INSTALLING THE REAR BRAKE CALIPER

1. Install:
Brake caliper "1"
G
(temporarily)
Copper washers
G
Brake hose "2"
G
Union bolt "3"
G
4-44
REAR BRAKE
New
New
New