Yamaha XS650SE, Shop Manual

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3.
4.
5.
6.
See “Caliper Replacement Pad” procedure
for parts to be replaced when pads are
replaced.
Replace piston and dust seals if damaged.
Inspect master cylinder body. Replace if
scratched. Clean all passages with new
brake fluid.
Inspect brake hoses. Replace every four
years or if cracked, frayed or damaged.
Check for wear and deflection of disc.
Wear limit:
1.5 mm (0.06 in)
1. Dial gauge
Maximum deflection: 0.15 mm(0.006 in)
Minimum disc thickness: 6.5 mm(0.26 in)
If disc is worn beyond minimum thickness
or deflection exceeds specified amount,
replace disc.
E. Brake reassembly
All internal parts should be cleaned in
new brake fluid. Internal parts should be
lubricated with brake fluid when installed.
Caliper reassembly
Replace the following parts whenever a
caliper is disassembled: bleed screw and
cap, boot bushing, piston seal, dust seal,
retaining ring.
(with 4. Dust seal
2. Bush boot
5.
Retaining ring
3. Piston seal
a. Install piston seal and piston. Place caliper
cylinder into caliper frame.
b. Install pad spring and retainer. Install dust
seal and clip.
c. Install pad spring and pads.
d. Install support bolt and remount caliper
on brackets.
Mounting bolt
Mounting bolt torque:
3.5 m-kg (25 ft-lb)
3.
4.
Attach brake hoses.
Master cylinder reassembly
Reassemble master cylinder.
2.