Yamaha Fz6n Manual
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4-25 FRONT AND REAR BRAKESCHAS Order Job / Part Q’ty Remarks Disassembling the front brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod1 1 1 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 EAS00585
4-26 FRONT AND REAR BRAKESCHAS Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Removing the rear brake master cylinder Brake fluid Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Union bolt Copper washer Brake hose Master cylinder assembly1 1 1 1 1 1 1 1 1Remove the parts in the order listed. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. For installation, reverse the removal procedure. 30 Nm (3.0 mkg, 22 ftlb) 23 Nm (2.3 mkg, 17 ftlb) EAS00586 REAR BRAKE MASTER CYLINDER
4-27 FRONT AND REAR BRAKESCHAS Order Job / Part Q’ty Remarks Disassembling the rear brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body1 1 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 EAS00587
4-28 AB CD FRONT AND REAR BRAKESCHAS NOTE: NOTE: EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: brake light switch coupler 1 (from the brake light switch) 2. Remove: union bolt 1 copper washers 2 brake hoses 3 To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 3. Remove: brake lever master cylinder bracket master cylinder assembly 4. Remove: circlip (from the master cylinder assembly) master cylinder kit EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: brake master cylinder 1 Damage / scratches / wear Replace. brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. AFront BRear 2. Check: brake master cylinder kit 1 Damage / scratches / wear Replace. CFront DRear
4-29 FRONT AND REAR BRAKESCHAS NOTE: 3. Check: rear brake fluid reservoir 1 Cracks / damage Replace. rear brake fluid reservoir diaphragm 2 Cracks / damage Replace. 4. Check: front brake master cylinder reservoir 1 Cracks / damage Replace. front brake master cylinder reservoir dia- phragm 2 Damage / wear Replace. 5. Check: brake hoses Cracks / damage / wear Replace. Refer to “CHECKING THE FRONT AND REAR BRAKE HOSES” in chapter 3. EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Remove: union bolt 1 copper washers 2 brake hose 3 To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 2. Disconnect: brake fluid reservoir hose 3. Remove: pin (from the brake pedal link) 4. Remove: rear brake master cylinder assembly 5. Remove: circlip (from the rear brake master cylinder assembly) master cylinder kit
4-30 FRONT AND REAR BRAKESCHAS a WARNING NOTE: 30 Nm (3.0 mkg, 22 ftlb) WARNING CAUTION: EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 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. Recommended brake fluid DOT 4 1. Install: master cylinder kit circlip New brake master cylinder 1 Install the brake master cylinder holder with the “UP” mark facing up. Align the end of the brake master cylinder holder with the punch mark a on the handle- bar. First, tighten the upper bolt, then the lower bolt. 2. Install: copper washers 1 New brake hose 2 union bolt 3 Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING” in chapter 2. When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a on the brake master cylinder.
4-31 FRONT AND REAR BRAKESCHAS NOTE: WARNING While holding the brake hose, tighten the union bolt as shown. 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 recom- mended brake fluid) Recommended brake fluid DOT 4 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 perfor- mance. When refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
4-32 FRONT AND REAR BRAKESCHAS 30 Nm (3.0 mkg, 22 ftlb) WARNING CAUTION: WARNING EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: brake master cylinder kit circlip dust boot 2. Install: copper washers New brake hoses union bolt Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING” in chapter 2. When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. 3. Fill: brake fluid reservoir (to the maximum level mark a) Recommended brake fluid DOT 4 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 perfor- mance. 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.
4-33 FRONT AND REAR BRAKESCHAS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Adjust: brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in chapter 3. Brake pedal position (below the top of the rider footrest) 25.8 mm (1.02 in) 7. Adjust: rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” in chapter 3.
4-34 FRONT AND REAR BRAKESCHAS Order Job / Part Q’ty Remarks 1 2 3 4 5 6Removing the front brake calipers Brake fluid Union bolt Copper washer Brake hose Brake caliper Brake pad Brake caliper bracket1 2 1 1 2 1Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. For installation, reverse the removal procedure. NOTE: 10 Nm (1.0 mkg, 72 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 40 Nm (4.0 mkg, 29 ftlb) 40 Nm (4.0 mkg, 29 ftlb) 4 Nm (0.4 mkg, 2.9 ftlb) EAS00613 FRONT BRAKE CALIPERS