Yamaha MM600D, Manual

Page: 212 / 282

206 CHAPTER ELEVEN
2. Disconnect the brake hose from the brake caliper. Tie a
small plastic bag around the end of the brake hose to pre-
vent brake fluid from dripping into the engine compart-
ment.
3. Remove the caliper retaining bolts (Figure
11).
4.
Remove the caliper.
5. To reinstall caliper, reverse the removal steps while
noting the following:
Tighten the caliper retaining bolts to 48 (35
Install the brake hose, with a sealing washer on each
side of the fitting, onto the caliper.
If the caliper has a projection (Figure 12) adjacent
to the brake hose end, make sure to position the hose
end so it contacts the projection.
Install the union bolt and tighten to
23
(17
If the brake hose was disconnected, bleed the brake
system as described in this chapter.
Caliper Overhaul
This procedure describes complete overhaul of the
brake caliper assembly. does not provide service
specifications for any caliper component; replace any part
that appears worn or
NOTE
Although the caliper has two halves, do not
attempt to remove the
that secure the
caliper halves together. Piston service is the
only procedure recommended by
Refer to
Figure 1.
1. Remove the caliper and brake pads as described
in
this
chapter.
2. Remove the caliper pistons as follows:
a. Place a rag or piece of wood between the pistons.
Remove the cap on each bleed screw (Figure 13).
c. Open the bleed screw on the side of the caliper for
the piston being removed.
Perform this step over and close to a workbench top.
Hold the caliper so that while removing the piston,
the piston is facing away from you.
WARNING
In the next step, the piston may shoot out of
the
half with considerable force.
Keep fingers out
of the way. Wear shop
gloves and apply air pressure gradually.
e. Direct compressed air in short spurts into the bleed
screw and force the piston out of the caliper half.
Remove the piston.
In the following step, do not use
a
sharp tool
to remove the piston seal from the caliper
bore. The bore can be easily scratched.
3. Carefully remove the piston seals from the seal
grooves with a piece of wood or plastic. Make sure new
piston seals are reinstalled.
4.
Check the piston and the piston bore for deep scratches
or other obvious wear marks. If either part is less than per-
fect, replace it.
5.
Remove the bleed screws and check them for wear or
damage. Clean the screws with compressed air.
6.
Inspect the caliper body for damage. The caliper body
is only available as a unit assembly.
7.
Inspect the hydraulic fluid passageway in the caliper
bore. Apply compressed air to the opening to clean it.
8.
Clean all parts (except brake pads) with DOT 4 brake
fluid.
9. Soak the new piston seals in fresh brake fluid. Coat the
inside of the cylinder with fresh brake
fluid before assem-
bling the parts.