Yamaha YFM660 01 User Manual

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CHASFRONT AND REAR BRAKES
***********************************************
Installation steps:

Connect a suitable hose 1
 tightly to the
brake caliper bleed screw 2
. Put the other
end of this hose into an open container.

Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.

Tighten the brake caliper bleed screw. 

Install new brake pads, new pad shim 3
 and
a new brake pad spring.

Install the holding bolts and brake caliper.
NOTE:
The arrow mark a
 on the pad shim must point
in the direction of the disc rotation.
***********************************************
T R..
Brake caliper bleed screw:
6 Nm (0.6 m  kg, 4.3 ft  lb)
T R..
Brake pad holding bolt:
18 Nm (1.8 m  kg, 13 ft  lb)
Brake caliper mounting bolt:
28 Nm (2.8 m  kg, 20 ft  lb)
3.Check:

Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
4.Check:

Brake lever operation
Soft or spongy feeling →
 Bleed the front
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3. 
						

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CHASFRONT AND REAR BRAKES
REPLACING THE REAR BRAKE PAD
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Remove:

Brake pads
aWear limit
NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.
2.Install:

Brake pads

Brake pad spring
NOTE:
Always install new brake pads, brake pad shim
and brake pad spring as a set.
***********************************************
Installation steps:

Connect a suitable hose 1
 tightly to the
brake caliper bleed screw 2
. Put the other
end of this hose into an open container.

Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.

Tighten the brake caliper bleed screw.

Install new brake pads, new pad shim 3
 and
a new brake pad spring.

Install a new lock washer, holding bolts and
brake caliper.
NOTE:
The arrow mark a
 on the pad shim must point
in the direction of the disc rotation.
T R..
Brake caliper bleed screw:
6 Nm (0.6 m  kg, 4.3 ft  lb) 
						

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CHASFRONT AND REAR BRAKES

Bend the lock washer tabs along a flat side
of the bolts.
***********************************************
T R..
Brake pad holding bolt:
18 Nm (1.8 m  kg, 13 ft  lb)
Brake caliper mounting bolt:
28 Nm (2.8 m  kg, 20 ft  lb)
3.Check:

Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
4.Check:

Brake pedal operation
Soft or spongy feeling →
 Bleed the rear
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3. 
						

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CHASFRONT AND REAR BRAKES
FRONT BRAKE MASTER CYLINDER
Order Job name/Part name Q’ty Remarks
Removing front brake master cylin-
derRemove the parts in the order below.
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm 1
3 Front brake switch 1
4 Brake lever 1
5 Union bolt 1
Refer to “INSTALLING THE FRONT 
BRAKE MASTER CYLINDER”. 6 Copper washer 2
7 Brake hose 1
8 Brake master cylinder bracket 1
9 Brake master cylinder 1
For installation, reverse the removal pro-
cedure.  
						

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CHASFRONT AND REAR BRAKES
Order Job name/Part name Q’ty Remarks
Disassembling the front brake mas-
ter cylinderRemove the parts in the order below.
1
 Dust boot 1
Refer to “ASSEMBLING THE FRONT 
AND REAR BRAKE MASTER CYLIN-
DER”. 2
 Circlip 1
3
  Brake master cylinder kit 1
For assembly, reverse the disassembly 
procedure. 
						

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CHASFRONT AND REAR BRAKES
REAR BRAKE MASTER CYLINDER
Order Job name/Part name Q’ty Remarks
Removing the rear brake master cyl-
inderRemove the parts in the order below.
Right footrest guard Refer to “SEAT, FENDERS AND FUEL 
TANK” in CHAPTER 3.
Brake fluid Drain.
1 Brake fluid reservoir cover 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Right footrest guard bracket 1 
						

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CHASFRONT AND REAR BRAKES
Order Job name/Part name Q’ty Remarks
8 Union bolt 1
Refer to “INSTALLING THE REAR 
BRAKE MASTER CYLINDER”. 9 Copper washer 2
10 Brake hose 1
11 Brake master cylinder 1
For installation, reverse the removal pro-
cedure. 
						

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CHASFRONT AND REAR BRAKES
Order Job name/Part name Q’ty Remarks
Disassembling the rear brake mas-
ter cylinderRemove the parts in the order below.
1
Hose joint 1
2
Brake master cylinder kit 1 Refer to “ASSEMBLING THE FRONT 
AND REAR BRAKE MASTER CYLIN-
DER”. 3
Brake master cylinder 1
For assembly, reverse the disassembly 
procedure. 
						

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CHASFRONT AND REAR BRAKES
CHECKING THE MASTER CYLINDER
1.Check:

Brake master cylinder 1
 
Wear/scratches →
 Replace the brake master
cylinder assembly.

Brake master cylinder body
Cracks/damage →
 Replace.

Brake fluid delivery passage
(brake master cylinder body)
Blockage →
 Blow out with compressed air.
ÈFront
ÉRear
È
É
2.Check:

Brake master cylinder kit
Scratches/wear/damage →
 Replace as a set.
ÈFront
ÉRear
É È
3.Check:

Front brake master cylinder reservoir 1
 

Front brake master cylinder reservoir dia-
phragm 2
 
Cracks/damage →
 Replace.
4.Check:

Rear brake fluid reservoir 1
 

Rear brake fluid reservoir diaphragm 2
 
Cracks/damage →
 Replace. 
						

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CHASFRONT AND REAR BRAKES
EB702060
ASSEMBLING THE FRONT AND REAR 
BRAKE MASTER CYLINDER
WARNING

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

Whenever a master cylinder is disassem-
bled, replace the piston seals and dust
seals.
Recommended brake fluid:
DOT 4
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1.Install:

Brake master cylinder 1
 
NOTE:
The “UP” mark on the brake master cylinder
bracket should face up.
T R..7 Nm (0.7 m  kg, 5.1 ft  lb)
2.Install:

Copper washers

Brake hose 

Union bolt 
NOTE:

Tighten the union bolt while holding the
brake hose as shown.

Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING”.
New
T R..27 Nm (2.7 m  kg, 19 ft  lb)