Yamaha XMAX YP125R - Service manual > Front brake

Removing the front brake pads
Removing the front brake pads

Removing the front brake master cylinder
Removing the front brake master cylinder

Disassembling the front brake master cylinder
Disassembling the front brake master cylinder

Removing the front brake caliper
Removing the front brake caliper

Disassembling the front brake caliper
Disassembling the front brake caliper

Introduction

WARNING

Disc brake components rarely require disassembly.

Therefore, always follow these preventive measures:

FIRST AID FOR BRAKE FLUID ENTERING THE EYES:

Checking the front brake disc

1. Remove:

2. Check:

Damage/galling → Replace.

3. Measure:

Out of specification → Correct the brake disc deflection or replace the brake disc.

Brake disc deflection limit 0.15 mm (0.0059 in)

a. Place the vehicle on a suitable stand so that the front wheel is elevated.

b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary.

c. Remove the brake caliper.

d. Hold the dial gauge at a right angle against the brake disc surface.

e. Measure the deflection 1.5 mm (0.06 in) below the edge of the brake disc.

Checking the front brake disc

4. Measure:

Measure the brake disc thickness at a few different locations.

Out of specification → Replace.

Brake disc thickness limit 4.5 mm (0.18 in)

Checking the front brake disc

5. Adjust:

a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.

c. Install the brake disc.

Front brake disc bolt 12 Nm (1.2 m*kgf, 8.7 ft*lbf) LOCTITE

TIP

Tighten the brake disc bolts in stages and in a crisscross pattern.

Checking the front brake disc

d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.

f. If the brake disc deflection cannot be brought within specification, replace the brake disc.

6. Install:

Replacing the front brake pads

TIP

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.

1. Measure:

Out of specification → Replace the brake pads as a set.

Brake pad lining thickness (inner) 5.0 mm (0.20 in)

Limit 1.5 mm (0.06 in)

Brake pad lining thickness (outer) 5.0 mm (0.20 in)

Limit 1.5 mm (0.06 in)

Replacing the front brake pads

2. Install:

TIP

Always install new brake pads, a new brake pad spring, and a new brake pad support as a set.

a. Connect a clear plastic hose "1" tightly to the bleed screw "2". Put the other end of the hose into an open container.

b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

Replacing the front brake pads

c. Tighten the bleed screw.

Bleed screw 6 Nm (0.6 m*kgf, 4.3 ft*lbf)

d. Install new brake pad support, new brake pad spring and new brake pads.

3. Install:

Front brake caliper bolt 40 Nm (4.0 m*kgf, 29 ft*lbf)

4. Check:

Below the minimum level mark "a" → Add the recommended brake fluid to the proper level.

Replacing the front brake pads

5. Check:

Soft or spongy feeling → Bleed the brake system.

Removing the front brake caliper

TIP

Before removing the brake caliper, drain the brake fluid from the entire brake system.

1. Remove:

TIP

Put the end of the brake hose into a container and pump out the brake fluid carefully.

Removing the front brake caliper

Disassembling the front brake caliper

1. Remove:

Disassembling the front brake caliper

a. Blow compressed air into the brake hose joint opening "a" to force out the pistons from the brake caliper.

WARNING

Disassembling the front brake caliper

b. Remove the brake caliper piston dust seals and brake caliper piston seals.

Checking the front brake caliper

Checking the front brake caliper

1. Check:

Rust/scratches/wear → Replace the brake caliper pistons.

Scratches/wear → Replace the brake caliper assembly.

Cracks/damage → Replace the brake caliper assembly.

Obstruction → Blow out with compressed air.

WARNING

Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and brake caliper piston seals.

Checking the front brake caliper

2. Check:

Cracks/damage → Replace.

Assembling the front brake caliper

WARNING

Recommended fluid DOT 4

Installing the front brake caliper

1. Install:

Front brake hose union bolt 23 Nm (2.3 m*kgf, 17 ft*lbf)

WARNING

Proper brake hose routing is essential to insure safe vehicle operation.

NOTICE

When installing the brake hose onto the brake caliper "1", make sure the brake pipe "a" touches the projection "b" on the brake caliper.

Installing the front brake caliper

2. Remove:

3. Install:

Brake pad pin 18 Nm (1.8 m*kgf, 13 ft*lbf)

Brake pad pin cap 3 Nm (0.3 m*kgf, 2.2 ft*lbf)

Front brake caliper bolt 40 Nm (4.0 m*kgf, 29 ft*lbf)

4. Fill:

Recommended fluid DOT 4

WARNING

NOTICE

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

5. Bleed:

6. Check:

Below the minimum level mark "a" → Add the recommended brake fluid to the proper level.

Installing the front brake caliper

7. Check:

Soft or spongy feeling → Bleed the brake system.

Removing the front brake master cylinder

TIP

Before removing the front brake master cylinder, drain the brake fluid from the entire brake system.

1. Remove:

TIP

To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

Removing the front brake master cylinder

Checking the front brake master cylinder

1. Check:

Damage/scratches/wear → Replace.

Obstruction → Blow out with compressed air.

2. Check:

Damage/scratches/wear → Replace.

3. Check:

4. Check:

Cracks/damage/wear → Replace.

Assembling the front brake master cylinder

WARNING

Recommended fluid DOT 4

Installing the front brake master cylinder

1. Install:

Brake master cylinder holder bolt 7 Nm (0.7 m*kgf, 5.1 ft*lbf)

TIP

Installing the front brake master cylinder

2. Install:

Brake hose union bolt 23 Nm (2.3 m*kgf, 17 ft*lbf)

WARNING

Proper brake hose routing is essential to insure safe vehicle operation.

NOTICE

When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection "a" as shown.

TIP

Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.

Installing the front brake master cylinder

3. Fill:

Recommended fluid DOT 4

WARNING

NOTICE

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

4. Bleed:

5. Check:

Below the minimum level mark "a" → Add the recommended brake fluid to the proper level.

Installing the front brake master cylinder

6. Check:

Soft or spongy feeling → Bleed the brake system.

See also:

 Yamaha XMAX YP125R - Service manual > Rear wheel

Removing the rear wheel and brake disc Removing the rear wheel

 Yamaha XMAX YP125R - Service manual > Rear brake

Removing the rear brake pads (YP125R) Removing the rear brake pads (YP250R) Removing the rear brake master cylinder Disassembling the rear brake master cylinder Removing the rear brake caliper (YP125R) Removing the rear brake caliper (YP250R) Disassembling the rear brake caliper (YP125R) Disassembling the rear brake caliper (YP250R)

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