Introduction; Checking The Rear Brake Disc; Replacing The Rear Brake Pads - Yamaha 2007 XP500 Service Manual

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INTRODUCTION

EWA14100
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
Never disassemble brake components un-
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less absolutely necessary.
If any connection on the hydraulic brake
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system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
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ponents.
Use only clean or new brake fluid for clean-
G
ing brake components.
Brake fluid may damage painted surfaces
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and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with
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the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
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THE EYES:
Flush with water for 15 minutes and get im-
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mediate medical attention.
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CHECKING THE REAR BRAKE DISC

1. Remove:
Rear wheel
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Refer to "REAR WHEEL" on page 4-16.
2. Check:
Brake disc
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Damage/galling → Replace.
3. Measure:
Brake disc deflection
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Out of specification → Correct the brake disc
deflection or replace the brake disc.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-26.
Brake disc deflection limit
0.15 mm (0.0059 in)
4. Measure:
Brake disc thickness
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Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-26.
Brake disc thickness limit
4.5 mm (0.18 in)
5. Adjust:
Brake disc deflection
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Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-26.
Brake disc bolt
18 Nm (1.8 m•kg, 13 ft•lb)
LOCTITE®
6. Install:
Rear wheel
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Refer to "REAR WHEEL" on page 4-16.
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REPLACING THE REAR BRAKE PADS

NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove:
Rear brake caliper retaining bolt (rear) "1"
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Brake caliper bracket bolts "2"
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Brake caliper "3"
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2
2. Remove:
Brake pads "1"
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Brake pad springs "2"
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3. Measure:
Brake pad wear limit "a"
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Out of specification → Replace the brake
4-39
REAR BRAKE
3
1