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Yamaha Fz6n Manual

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    Page
    of 432
    							4-35
    FRONT AND REAR BRAKESCHAS
    Order Job / Part Q’ty Remarks
    Disassembling the front brake 
    calipers
    Brake pad
    Brake caliper piston
    Brake caliper piston seal
    Brake pad spring
    Bleed screw2
    2
    4
    1
    1Disassemble the parts in the order listed.
    The following procedure applies to both of
    the front brake calipers.
    For assembly, reverse the disassembly 
    procedure.
    NOTE:
    1
    2
    3
    4
    5
    6 Nm (0.6 mkg, 4.3 ftlb)
    EAS00615 
    						
    							4-36
    FRONT AND REAR BRAKESCHAS
    Order Job / Part Q’ty Remarks
    1
    2
    3
    4Removing the rear brake caliper
    Brake fluid
    Union bolt
    Copper washer
    Brake hose
    Brake caliper1
    2
    1
    1Remove the parts in the order listed.
    Drain.
    Refer to “BLEEDING THE HYDRAULIC
    BRAKE SYSTEM” in chapter 3.
    For installation, reverse the removal 
    procedure.
    22 Nm (2.2 mkg, 16 ftlb)
    27 Nm (2.7 mkg, 20 ftlb)
    30 Nm (3.0 mkg, 22 ftlb)
    EAS00616
    REAR BRAKE CALIPER 
    						
    							4-37
    FRONT AND REAR BRAKESCHAS
    Order Job / Part Q’ty Remarks
    Disassembling the rear brake caliper
    Screw plug
    Brake pad pin
    Brake pad
    Brake pad shim
    Brake pad spring
    Brake caliper piston
    Brake caliper piston seal
    Bleed screw1
    1
    2
    4
    1
    1
    2
    1Disassemble the parts in the order listed.
    For assembly, reverse the disassembly 
    procedure.
    1
    2
    3
    4
    5
    6
    7
    8
    6 Nm (0.6 mkg, 4.3 ftlb)
    17 Nm (1.7 mkg, 12 ftlb)
    3 Nm (0.3 mkg, 2.2 ftlb)
    EAS00617 
    						
    							4-38
    FRONT AND REAR BRAKESCHAS
    NOTE:
    NOTE:
    WARNING
    EAS00625
    DISASSEMBLING THE FRONT BRAKE 
    CALIPERS
    The following procedure applies to both of the
    brake calipers.
    Before disassembling the brake caliper, drain
    the brake fluid from the entire brake system.
    1. Remove:
    union bolt 
    1
    copper washers 2
    brake hose 3
    Put the end of the brake hose into a container
    and pump out the brake fluid carefully.
    2. Remove:
    brake caliper pistons 
    1
    brake caliper piston seals 2
    a. Secure the right side brake caliper pistons
    with a piece of wood 
    a.
    b. Blow compressed air into the brake hose
    joint opening 
    b to force out the left side pis-
    tons from the brake caliper.
    Cover the brake caliper piston with a rag.
    Be careful not the get injured when the pis-
    tons are expelled from the brake caliper.
    Never try to pry out the brake caliper pis-
    tons.
    c. Remove the brake caliper piston seals. 
    						
    							4-39
    FRONT AND REAR BRAKESCHAS
    NOTE:
    NOTE:
    WARNING
    EAS00627
    DISASSEMBLING THE REAR BRAKE 
    CALIPER
    Before disassembling the brake caliper, drain
    the brake fluid from the entire brake system.
    1. Remove:
    union bolt 
    1
    copper washers 2
    brake hose 3
    brake caliper 4
    Put the end of the brake hose into a container
    and pump out the brake fluid carefully.
    2. Remove:
    brake caliper piston 
    1
    brake caliper piston seals 2
    a. Blow compressed air into the brake hose
    joint opening 
    a to force out the pistons from
    the brake caliper.
    Cover the brake caliper piston with a rag.
    Be careful not to get injured when the pis-
    tons are expelled from the brake caliper.
    Never try to pry out the brake caliper pis-
    tons.
    b. Remove the brake caliper piston seals. 
    						
    							4-40
    A
    B
    FRONT AND REAR BRAKESCHAS
    WARNING
    EAS00633
    CHECKING THE FRONT AND REAR BRAKE
    CALIPERS
    Recommended brake component
    p
    replacement schedule
    Brake padsIf necessary
    Piston sealsEvery two years
    Brake hosesEvery four years
    Brake fluidEvery two years
    and whenever the
    brake is disas-
    sembled
    1. Check:
    brake caliper pistons 
    1
    Rust / scratches / wear  Replace the brake
    caliper pistons.
    brake caliper cylinders 
    2
    Scratches / wear  Replace the brake cali-
    per assembly.
    brake caliper body 
    3
    Cracks / damage  Replace the brake cali-
    per assembly.
    brake fluid delivery passages
    (brake caliper body)
    Obstruction  Blow out with compressed air.
    Whenever a brake caliper is disassembled,
    replace the brake caliper piston seals.
    AFront
    BRear
    2. Check:
    Rear brake caliper brackets 
    1
    Cracks / damage  Replace. 
    						
    							4-41
    FRONT AND REAR BRAKESCHAS
    WARNING
    22 Nm (2.2 mkg, 16 ftlb)
    40 Nm (4.0 mkg, 29 ftlb)
    30 Nm (3.0 mkg, 22 ftlb)
    WARNING
    CAUTION:
    EAS00638
    ASSEMBLING AND INSTALLING
    THE FRONT BRAKE CALIPERS
    The following procedure applies to both of the
    brake calipers.
    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
    to swell and distort.
    Whenever a brake caliper is disassembled,
    replace the brake caliper piston seals.
    Recommended brake fluid
    DOT 4
    1. Install:
    brake caliper bracket
    brake pads
    brake caliper 
    1
    copper washers New
    brake hose 
    2
    union bolt 3
    Proper brake hose routing is essential to in-
    sure safe motorcycle operation. Refer to
    “CABLE ROUTING” in chapter 2.
    When installing the brake hose onto the
    brake caliper 
    1, make sure the brake pipe a
    touches the projection b on the brake cali-
    per. 
    						
    							4-42
    FRONT AND REAR BRAKESCHAS
    WARNING
    CAUTION:
    2. Fill:
    brake master cylinder reservoir
    (with the specified amount of the recom-
    mended brake fluid)
    Recommended brake fluid
    DOT 4
    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 perfor-
    mance.
    When refilling, be careful that water does
    not enter the brake master cylinder reser-
    voir. Water will significantly lower the boil-
    ing point of the brake fluid and could cause
    vapor lock.
    Brake fluid may damage painted surfaces
    and plastic parts. Therefore, always clean
    up any spilt brake fluid immediately.
    3. Bleed:
    brake system
    Refer to “BLEEDING THE HYDRAULIC
    BRAKE SYSTEM” in chapter 3.
    4. 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” in chapter 3.
    5. Check:
    brake lever operation
    Soft or spongy feeling  Bleed the brake
    system.
    Refer to “BLEEDING THE HYDRAULIC
    BRAKE SYSTEM” in chapter 3. 
    						
    							4-43
    FRONT AND REAR BRAKESCHAS
    WARNING
    27 Nm (2.7 mkg, 20 ftlb)
    22 Nm (2.2 mkg, 16 ftlb)
    30 Nm (3.0 mkg, 22 ftlb)
    WARNING
    CAUTION:
    EAS00642
    ASSEMBLING AND INSTALLING THE REAR
    BRAKE CALIPER
    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
    to swell and distort.
    Whenever a brake caliper is disassembled,
    replace the brake caliper piston seals.
    Recommended brake fluid
    DOT 4
    1. Install:
    brake caliper 
    1
    (front)
    (rear)
    brake pad pin
    screw plug
    copper washers 
    New
    brake hose 
    2
    union bolt 3
    Proper brake hose routing is essential to in-
    sure safe motorcycle operation. Refer to
    “CABLE ROUTING”.
    When installing the brake hose onto the
    brake caliper 
    1, make sure the brake pipe a
    touches the projection b on the brake cali-
    per.
    2. Fill:
    brake fluid reservoir
    (with the specified amount of the recom-
    mended brake fluid)
    Recommended brake fluid
    DOT 4 
    						
    							4-44
    FRONT AND REAR BRAKESCHAS
    WARNING
    CAUTION:
    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 perfor-
    mance.
    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.
    Brake fluid may damage painted surfaces
    and plastic parts. Therefore, always clean
    up any spilt brake fluid immediately.
    3. Bleed:
    brake system
    Refer to “BLEEDING THE HYDRAULIC
    BRAKE SYSTEM” in chapter 3.
    4. 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” in chapter 3.
    5. Check:
    brake pedal operation
    Soft or spongy feeling  Bleed the brake
    system.
    Refer to “BLEEDING THE HYDRAULIC
    BRAKE SYSTEM” in chapter 3. 
    						
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