Yamaha Tracer MT09TRA - Service manual > Disassembling the rear brake caliper

1. Remove:

• Brake caliper piston "1"
• Brake caliper piston dust seal "2"
• Brake caliper piston seal "3"

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

WARNING

• Cover the brake caliper piston with a rag.

  Be careful not to get injured when the piston is expelled from the brake caliper.

• Never try to pry out the brake caliper piston.

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

Checking the rear brake caliper

1. Check:

• Brake caliper piston "1"

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

• Brake caliper cylinder "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

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

2. Check:

Rear brake caliper bracket "1" Cracks/damage →   Replace.

Refer to "REAR WHEEL"

Assembling the rear brake caliper

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 as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal.

Specified brake fluid DOT 4

Installing the rear brake caliper

1. Install:

• Rear brake caliper "1" (temporarily)
• Brake hose gaskets
• Brake hose "2"
• Brake hose union bolt "3"

Rear brake hose union bolt 30 Nm (3.0 m*kgf, 22 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" passes between the projections "b" on the brake caliper.

2. Remove:

• Rear brake caliper

3. Install:

• Brake pad insulators
• Brake pad shims (onto the brake pads)
• Brake pad spring (into the rear brake caliper)
• Brake pads
• Rear brake caliper

Refer to "REPLACING THE REAR BRAKE PADS"

Rear brake caliper bolt (front) 27 Nm (2.7 m*kgf, 20 ft*lbf)

Rear brake caliper bolt (rear) 22 Nm (2.2 m*kgf, 16 ft*lbf)

LOCTITE Rear brake pad retaining bolt 17 Nm (1.7 m*kgf, 12 ft*lbf)

Rear brake caliper screw plug 2.5 Nm (0.25 m*kgf, 1.8 ft*lbf)

4. Fill:

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

Specified brake 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 fluid 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

Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)"

6. Check:

• Brake fluid level

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

Refer to "CHECKING THE BRAKE FLUID LEVEL"

7. Check:

• Brake pedal operation

Soft or spongy feeling → Bleed the brake system.

Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)"

See also: