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"

Rear 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.

2. Remove:

• Rear brake caliper

3. Install:

• Brake pad supports
• Brake pad shims
• Brake pads
• Rear brake caliper

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

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

4. Fill:

• Brake master cylinder reservoir (with the specified amount of the recommended brake fluid)

Recommended fluid DOT 4

WARNING

• 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 performance.
• When refilling, be careful that water does not enter the brake master cylinder reservoir.

  Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

NOTICE

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

5. Bleed:

• Brake system

6. Check:

• Brake fluid level

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

7. Check:

• Brake lever operation

Soft or spongy feeling → Bleed the brake system.

Removing the rear brake master cylinder

TIP

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

1. Remove:

• Brake hose union bolt "1"
• Copper washers "2"
• Brake hose "3"

TIP

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

Checking the rear brake master cylinder

1. Check:

• Brake master cylinder

Damage/scratches/wear → Replace.

• Brake fluid delivery passages brake master cylinder body)

Obstruction → Blow out with compressed air.

2. Check:

• Brake master cylinder kit

Damage/scratches/wear → Replace.

3. Check:

• Brake master cylinder reservoir cap
• Brake master cylinder reservoir diaphragm holder
• Brake master cylinder reservoir diaphragm Damage/wear → Replace.

4. Check:

• Rear brake hose

Cracks/damage/wear → Replace.

Assembling the rear brake master cylinder

WARNING

• Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.
• Never use solvents on internal brake components.

Recommended fluid DOT 4

Installing the rear brake master cylinder

1. Install:

• Brake master cylinder "1"
• Brake master cylinder holder

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

TIP

• Align the projection "a" on the brake master cylinder with the hole "b" in the handlebar.
• First, tighten the front bolt, then the rear bolt.

2. Install:

• Copper washers "1"
• Rear brake hose "2"
• Brake hose union bolt "3"

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.

3. Fill:

• Brake master cylinder reservoir (with the specified amount of the recommended brake fluid)

Recommended fluid DOT 4

WARNING

• 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 performance.
• When refilling, be careful that water does not enter the brake master cylinder reservoir.

  Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

NOTICE

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

4. Bleed:

• Brake system

5. Check:

• Brake fluid level

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

6. Check:

• Brake lever operation

Soft or spongy feeling → Bleed the brake system.

See also: