Checking The Brake Pipes; Installing The Hydraulic Unit Assembly - Yamaha 2012 TMAX XP500A Service Manual

EAS59C2403

CHECKING THE BRAKE PIPES

The following procedure applies to all of the
brake pipes.
1. Check:
• Brake pipe end (flare nut)
Damage → Replace the hydraulic unit,
brake pipes, and related parts as a set.
EAS59C2404
INSTALLING THE HYDRAULIC UNIT
ASSEMBLY
1. Install:
• Hydraulic unit assembly
ECA4B56016
Do not remove the rubber plugs or bolts
(M10 × 1.0) installed in the flare nut holes
before installing the hydraulic unit assem-
bly.
TIP
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses or
brake pipes when installing the hydraulic unit
assembly.
2. Remove:
• Rubber plugs or bolts (M10 × 1.0)
3. Connect:
• ABS ECU coupler "1"
TIP
Push down the coupler ejection slider until a
click is heard, making sure that is installed
securely.
ABS (ANTI-LOCK BRAKE SYSTEM)
4. Install:
• Rear brake pipe/joint assembly "1"
• Rear brake pipe/joint assembly bolt
• Brake hose gaskets
• Brake hose union bolt "2"
Rear brake pipe/joint assembly
flare nut
Rear brake pipe/joint assembly
bolt
Brake hose union bolt
ECA59C2401
If the brake pipe flare nut does not turn eas-
ily, replace the hydraulic unit, brake pipes,
and related parts as a set.
TIP
• When installing the rear brake pipe/joint
assembly (hydraulic unit to rear brake hose),
temporarily tighten the flare nut and rear
brake pipe/joint assembly bolt first. After that,
tighten the flare nut and then the rear brake
pipe/joint assembly bolt to the specified
torque.
• When tightening the brake hose union bolt
"2", make sure that the metal part "a" of the
brake hose touches the hydraulic unit
assembly bracket "b".
5. Install:
• Rear brake hose (rear brake master cylin-
der to hydraulic unit) "1"
• Front brake hose (front brake master cyl-
inder to hydraulic unit) "2"
• Front brake hose (hydraulic unit to front
brake hose joint) "3"
• Brake hose gaskets
• Brake hose union bolts
4-71
New
16 Nm (1.6 m·kgf, 12 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
30 Nm (3.0 m·kgf, 22 ft·lbf)
New