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)

Introduction

WARNING

Disc brake components rarely require disassembly.

Therefore, always follow these preventive measures:

• Never disassemble brake components unless absolutely necessary.
• If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
• Never use solvents on internal brake components.
• Use only clean or new brake fluid for cleaning brake components.
• Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with the eyes as it can cause serious injury.

FIRST AID FOR BRAKE FLUID ENTERING THE EYES:

• Flush with water for 15 minutes and get immediate medical attention.

Checking the rear brake disc

1. Remove:

• Rear wheel

2. Check:

• Brake disc

Damage/galling → Replace.

3. Measure:

• Brake disc deflection

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

Brake disc deflection limit 0.25 mm (0.0098 in) (YP125R) 0.15 mm (0.0059 in) (YP250R)

4. Measure:

• Brake disc thickness

Measure the brake disc thickness at a few different locations.

Out of specification → Replace.

Brake disc thickness limit 4.5 mm (0.18 in)

5. Adjust:

• Brake disc deflection

Rear brake disc bolt 23 Nm (2.3 m*kgf, 17 ft*lbf) LOCTITE

6. Install:

• Rear wheel

Replacing the rear brake pads (YP125R)

TIP

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

1. Measure:

• Brake pad wear limit "a"

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

Brake pad lining thickness (inner) 7.3 mm (0.29 in)

Limit 0.8 mm (0.03 in)

Brake pad lining thickness (outer) 7.3 mm (0.29 in)

Limit 0.8 mm (0.03 in)

2. Install:

• Brake pad spring
• Brake pads

TIP

Always install new brake pads and a new brake pad spring 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.

c. Tighten the bleed screw.

Bleed screw 14 Nm (1.4 m*kgf, 10 ft*lbf)

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

3. Install:

• Brake pad pin
• Brake pad clip
• Rear brake caliper
• Rear brake caliper bolts

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

4. Check:

• Brake fluid level

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

5. Check:

• Brake lever operation

Soft or spongy feeling → Bleed the brake system.

Replacing the rear brake pads (YP250R)

TIP

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

1. Measure:

• Brake pad wear limit "a"

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

Brake pad lining thickness (inner) 5.3 mm (0.21 in)

Limit 0.8 mm (0.03 in)

Brake pad lining thickness (outer) 5.3 mm (0.21 in)

Limit 0.8 mm (0.03 in)

2. Install:

Brake pad supports

Brake pad shims (onto the brake pads)

Brake pads

TIP

Always install new brake pads, brake pad shims, and brake pad supports 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.

c. Tighten the bleed screw.

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

d. Install new brake pad shims onto each new brake pad.

e. Install new brake pad supports and new brake pads.

3. Install:

• Rear brake caliper
• Rear brake caliper retaining bolts

Rear brake caliper retaining bolt 27 Nm (2.7 m*kgf, 19 ft*lbf)

4. Check:

• Brake fluid level

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

5. Check:

• Brake lever operation

Soft or spongy feeling → Bleed the brake system.

• Removing the rear brake caliper
• Installing the rear brake caliper

See also: