Yamaha XT250X - Assembling the Front Brake Caliper; Installing the Front Brake Caliper

FRONT BRAKE
4-20
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
EWA13610
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
2. Check:
● Brake caliper bracket
Cracks/damage → Replace.
EAS22400
ASSEMBLING THE FRONT BRAKE CALIPER
WARNING
EWA13620
● 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.
EAS22420
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
● Front brake caliper bracket
● Front brake caliper
(temporarily)
● Copper washers
●
Front brake hose
● Union bolt
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CA-
BLE ROUTING” on page 2-25.
CAUTION:
ECA14170
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:
●
Front brake caliper
3. Install:
● Brake pad springs
● Front brake pad
● Front brake caliper
●
Brake caliper support bolt
Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-18.
4. Fill:
● Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13090
● Use only the designated brake fluid. Other
Recommended fluid
DOT 4
2
1
3
Front brake caliper bracket bolt
40 Nm (4.0 m•kg, 29 ft•lb)
Union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
Brake caliper support bolt
32 Nm (3.2 m•kg, 23 ft•lb)
Recommended fluid
DOT 4
New
T
R
.
.
1
b
a
T
R
.
.