Removing The Front Brake Calipers; Disassembling The Front Brake Calipers - Yamaha 2009 XP500Y TMAX Service Manual

e. Install the brake pad pin and brake pad clips.
L LLL L LLL L L LLL L L LLL L
3. Install:
• Front brake caliper
Front brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb)
4. Check:
• Brake fluid level
Below the minimum level mark "a" → Add the
recommended brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-21.
a
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-23.
EAS22300

REMOVING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Front brake hose holder bolt "1"
• Brake hose union bolt "2"
• Brake hose gaskets "3"
• Front brake hose "4"
a
L LLL L L LLL L LLL
4-25
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
1
2
EAS22360
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
• Brake caliper pistons "1"
• Brake caliper piston dust seals "2"
• Brake caliper piston seals "3"
2
1
3
2
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a. Blow compressed air into the brake hose joint
opening "a" to force out the pistons from the
brake caliper.
EWA4B51005
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.
• Do not loosen the bolts "4".
FRONT BRAKE
4
3
2
3
1
2
M MMM M M MMM M MMM