Yamaha MM700A, Manual, Page: 209 / 282

HYDRAULIC BRAKE PAD REPLACEMENT
There is no recommended time interval for changing
the brake pads on the main brake. Pad wear depends
greatly on riding habits and conditions. Always replace
both pads in the caliper at the same time.
The brake pads on the parking brake are not renewable;
replace the brake caliper lever arms if the pads are exces-
sively worn.
Refer to
Figure 1 for this procedure. The brake caliper
(Figure 2) is mounted on the chaincase.
NOTE
It is not necessary to disconnect the brake
hose from the brake when replacing the
brake pads.
1.
Open and secure the shroud.
Unscrew the caliper mounting bolts
(Figure 3).
NOTE
Do not operate the brake lever
ing the brake caliper
in
Step 3. Operating
the brake lever forces the piston out of the
caliper. Place a piece of wood
the
pads to prevent the piston from un-
seating from the accidental use o f the brake
lever.
3. Lift the brake calipcr assembly off the brake disc.
4. Clean any debris off the caliper assembly.
5. Unscrew the retaining pin lockscrew (Figure 4), then
unscrew the brake pad retaining pin behind the lockscrew.
6. Remove the pad spring, brake pads and shims (Figure
Check the brake pad friction surface for scoring,
cracks or excessive wear. Minimum allowable brake pad
thickness
(Figure 6) is 4.2 (0.17 in.). Replace both
brake pads as a set.
8. When new brake pads are installed in the caliper the
master cylinder brake fluid will rise as the calipcr pistons
are repositioned. Clean the top of the master cylinder of
all dirt. Remove the cover
(Figure 7) and diaphragm from
the master cylinder and slowly push each caliper piston
(Figure 8) into the calipcr. Constantly check the reservoir
to make sure brake fluid does not overflow. Remove the
fluid, if necessary, before it overflows. The piston should
move freely in the caliper bore. If the piston does not
move smoothly and it is sticking in the caliper, remove the
caliper as described in
Caliper Overhaul in this chapter.
9. Install brake pads as follows:
a. Assemble each brake pad with the shims as shown
in Figure 1. Note that the tabs on the outer shim fit
over the inner shim and brake pad (Figure 9).
Install the brake pads and shims into the caliper so
the friction surface on both pads face each other.
c. Install the pad retaining spring plate (Figure 10) so
the tabs fit into the recesses in the caliper.
d. Install the brake pad retaining pin and the retaining
pin lockscrew
(Figure 4).
10. Place the brake caliper assembly over the brake disc
so a brake pad is located on each side of the disc. Do not
force the brake caliper over the disc in order to not dam-
age the brake pads. If the caliper is difficult to install, the
piston needs to be pushed farther into the caliper bore.
11. Install the caliper retaining screws and tighten to 48
(35
12. Actuate the brake lever as many times as needed to
refill the cylinder in the caliper and correctly position the
pads.
13. Refill the master cylinder reservoir, if necessary, to
maintain the correct brake fluid level. Install the dia-
phragm and top cover.
Use
fluid
from a sealed container
DOT 4 only for disc
brakes). types may vaporize and
cause failure. Do not intermix
ent brands or types
as they may not
com-
patible. Do not intermix a silicone
(DOT
5) fluid as it can cause brake
component damage leading to brake system
failure.
Do not operate the snowmobile until the
brake
is operating correctly with full hy-
draulic advantage. I f necessary, bleed the
brake system as described in this chapter.
BRAKE
1. Open and secure the shroud.
NOTE
removal is access to
other components, hut caliper service
is
not
required, it may be possible to relocate the
caliper without disconnecting the
hose from the caliper.
DO NOT allow the
caliper to the brake hose.
NOTE
Be prepared to catch fluid when dis-
connecting the hose.