Yamaha YZ 2020 Series, Owner'S Service Manual

Page: 134 / 376

FRONT BRAKE
4-20
EAM30032
CHECKING THE FRONT BRAKE CALIPER
1. Check:
•
Brake caliper piston “1”
Rust/scratches/wear

Replace the brake
caliper piston.
• Brake caliper cylinder “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
EWA19220
When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
brake caliper piston dust seal with new ones.
2. Check:
•
Brake caliper bracket
Crack/damage

Replace.
EAM30033
ASSEMBLING THE FRONT BRAKE CALIPER
WARNING
EWA19230
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for
cleaning and lubricating.
• Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.
• When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
brake caliper piston dust seal with new
ones.
EAM30035
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
•
Front brake caliper bracket
• Front brake caliper
(temporarily)
• Copper washer
•
Brake hose
• Union bolt
WARNING
EWA13531
Proper brake hose routing is essential to in-
sure safe vehicle operation.
NOTICE
ECA24460
Make sure that the pipe portion “a” of the
brake hose touches the projection “b” on the
brake caliper.
2. Install:
• Front brake caliper
•
Brake pad spring
• Brake pad
•
Brake pad pin
• Brake hose holder
Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-23.
3. Tighten:
• Brake hose holder bolt “1”
TIP
Make sure that the brake hose holder “2” is in-
Specified brake fluid
DOT 4
2
1 1
3
Front brake caliper bracket
28 N·m (2.8 kgf·m, 21 lb·ft)
Brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
Brake pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
Brake hose holder bolt
9 N·m (0.9 kgf·m, 6.6 lb·ft)
New
T
R
.
.
a
b
T
R
.
.
T
R
.
.