ASSEMBLING THE FRONT BRAKE CALIPER
WARNING
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.
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
Brake caliper
(temporarily)
Copper washers
Brake hose
Brake hose union bolt
CAUTION:
When installing the brake hose onto the
brake caliper “1”
, make sure the brake pipe
“a”
touches the projection
“b” on the brake
caliper.
2. Remove:
Brake caliper
3. Install:
Brake pad spring
Brake pads
Brake caliper
Brake hose holder
Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-20.
4. Fill:
Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts.Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-18.
6. Check:
Brake fluid level
Below the minimum level mark “a”
→
Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-17.
Recommended fluid
DOT 3 or
4
DOT
T
R
.
.
Brake hose union bolt
26 Nm (2.6 m·kg, 19 ft·lb)
New
a
b
1
T
R
.
.
Brake caliper bolt
35 Nm (3.5 m·kg, 25 ft·lb)
Brake hose holder
7 Nm (0.7 m·kg, 5.1 ft·lb)
Recommended fluid
DOT 3 or
4
DOT
4-20
4-21
FRONT BRAKE
FRONT BRAKE
sssssssssssssssssssssssssssssssssssssss
REMOVING THE FRONT BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
Brake hose union bolt
Copper washers
Brake hose
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
DISASSEMBLING THE FRONT BRAKE
CALIPER
1. Remove:
Brake caliper pistons “1”
Brake caliper piston seals“2”
Brake caliper dust seals“3”
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
WARNING
Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston seals and
dust seals.
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
Whenever a brake caliper is disassembled,
replace the piston seals and dust seals.
2. Check:
Brake caliper bracket
Cracks/damage
→
Replace.
Brake pads
If necessary
Piston seals
Every two years
Dust seals
Every two years
Brake hose
Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
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Summary of Contents for YZF-R15
Page 1: ...2008 SERVICE MANUAL YZF R15 20P F8197 E0 ...
Page 33: ...2 14 ELECTRICAL SPECIFICATIONS Coil resistance 54 0 66 0 Fuse 20 0A Ω Fuse ...
Page 46: ...2 27 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION DIAGRAMS A 1 2 3 4 5 6 7 ...
Page 48: ...2 29 LUBRICATION POINTS AND LUBRICANT TYPES 1 2 3 4 ...
Page 49: ...2 30 LUBRICATION POINTS AND LUBRICANT TYPES 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...
Page 50: ...2 31 COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 2 3 4 1 5 7 6 4 ...
Page 52: ...2 33 CABLE ROUTING CABLE ROUTING 1 5 2 3 6 4 8 7 ...
Page 54: ...2 35 CABLE ROUTING A A B B C C A A C C B B A B C 1 2 3 4 5 4 5 6 6 7 8 9 10 11 10 11 12 12 ...
Page 56: ...2 37 CABLE ROUTING 1 2 5 4 3 ...
Page 60: ...2 41 CABLE ROUTING A A B C D E 1 2 3 4 5 6 7 8 9 10 A ...
Page 121: ...4 24 FRONT BRAKE Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 ...
Page 249: ...7 8 THROTTLE BODY ...
Page 250: ...7 9 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 1 2 5 4 5 6 3 2 1 6 4 3 ...
Page 257: ......
Page 269: ...8 12 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Battery 42 Fuse ...
Page 271: ...8 14 CHARGING SYSTEM ...
Page 275: ...8 18 LIGHTING SYSTEM ...
Page 285: ...8 28 COOLING SYSTEM ...
Page 311: ...8 54 FUEL PUMP SYSTEM ...