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

2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
• Brake master cylinder reservoir diaphragm
Cracks/damage → Replace.
4. Check:
• Brake hose
Cracks/damage/wear → Replace.
EAS22730
ASSEMBLING THE REAR 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
EAS22750
INSTALLING THE REAR 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
"UP" mark "a" facing up.
• Align the end of the brake master cylinder hold-
er with the punch mark "b" on the handlebar.
• First, tighten the upper bolt, then the lower bolt.
b
a
2
2. Install:
• Brake hose gaskets "1"
1
New
4-42
• Rear brake hose "2"
• Brake hose union bolt "3"
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EWA13530
WARNING
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 to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
New 1
3
a
2
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 4
EWA4B51011
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
REAR BRAKE