Yamaha XMAX YP125R - Service manual > Removing the rear 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 rear brake caliper

A. YP125R

B. YP250R

Disassembling the rear brake caliper (YP250R only)

1. Remove:

Disassembling the rear brake caliper (YP250R only)

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

WARNING

Disassembling the rear brake caliper (YP250R only)

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

Checking the rear brake caliper (YP125R)

Checking the rear brake caliper (YP125R)

1. Check:

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

Cracks/damage → Replace the brake caliper assembly.

(brake caliper body) Obstruction → Blow out with compressed air.

Checking the rear brake caliper (YP125R)

Checking the rear brake caliper (YP250R)

Checking the rear brake caliper (YP250R)

1. Check:

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

Scratches/wear → Replace the brake caliper assembly.

Cracks/damage → Replace the brake caliper assembly.

(brake caliper body) 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 rear brake caliper (YP250R)

2. Check:

Cracks/damage → Replace.

Assembling the rear brake caliper

WARNING

Recommended fluid DOT 4

Installing the rear brake caliper (YP125R)

1. Install:

Brake hose union bolt 28 Nm (2.8 m*kgf, 20 ft*lbf)

Installing the rear brake caliper (YP125R)

WARNING

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

NOTICE

While holding the brake hose, tighten the union bolt within the angle range shown in the illustration.

Installing the rear brake caliper (YP125R)

2. Remove:

3. Install:

Rear 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 rear brake caliper (YP125R)

7. Check:

Soft or spongy feeling → Bleed the brake system.

See also:

 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)

 Yamaha XMAX YP125R - Service manual > Installing the rear brake caliper

1. Install: Rear brake caliper "1" (temporarily) Copper washers "2" Rear brake hose "3" Brake hose union bolt "4"

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