Yamaha XV19SX(C), Service Manual

Page: 196 / 494

FRONT BRAKE
4-43
b. Remove the brake caliper piston seals and
dust seals.
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EAS22390
CHECKING THE FRONT BRAKE CALIPERS
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear
→
Replace the brake
caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear
→
Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage
→
Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction
→
Blow out with compressed air.
WARNING
EWA1D77003
Whenever a brake caliper is disassembled,
replace the piston seals and dust seals.
EAS22410
ASSEMBLING THE FRONT BRAKE
CALIPERS
WARNING
EWA1D77004
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the piston seals
and dust seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston seals and
dust seals.
EAS22440
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Install:
• Front brake caliper “1”
(temporarily)
• Copper washers
• Front brake hose “2”
• Front brake hose union bolt “3”
WARNING
EWA1D77008
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))” on page 2-51
and “CABLE ROUTING (for XV19CS(C)/
XV19C(C))” on page 2-67.
Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Dust seals Every two years
Brake hoses Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
a
Recommended fluid
DOT 4
T
R
.
.
Front brake hose union bolt
32 Nm (3.2 m·kg, 23 ft·lb)
2
1
1
3
New