Checking The Front Brake Master Cylinder; Assembling The Front Brake Master Cylinder; Installing The Front Brake Master Cylinder - Yamaha 2009 XP500Y TMAX Service Manual

EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace.
• Brake master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Brake hose
Cracks/damage/wear → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
EWA13520
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.
Recommended fluid
DOT 4
EAS22530
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder "1"
• Brake master cylinder holder "2"
Brake master cylinder holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
TIP
• Install the brake master cylinder holder with the
2 2
"UP" mark "a" facing up.
• Align the end of the brake master cylinder hold-
1 1
er with the punch mark "b" on the handlebar.
3 3
• First, tighten the upper bolt, then the lower bolt.
2. Install:
• Brake hose gaskets "1"
• Front brake hose "2"
• Brake hose union bolt "3"
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-35.
ECA14160
NOTICE
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection "a" as shown.
TIP
Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
4-28
FRONT BRAKE
b
1
New
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
WARNING
a
2
New
1 1
3
3
2 2
a