Yamaha YZF-R125 Service Manual: Installing the rear brake caliper

Yamaha YZF-R125 Service Manual / Chassis / Rear brake / Installing the rear brake caliper

1. Install:

Brake caliper "1"

Copper washers
Brake hose "2"
Union bolt "3"

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to "CABLE ROUTING" on page 2-33.

CAUTION:

When installing the brake hose onto the brake caliper, be sure to position the brake pipe "a" into the slot "b" in the brake caliper.

Installing the rear brake caliper

2. Install:

Brake pad spring
Brake pads
Brake pad retaining bolts
Rear brake caliper Refer to "REPLACING THE REAR BRAKE PADS" on page 4-33.

3. Install:

Rear wheel Refer to "REAR WHEEL" on page 4-12.

4. Fill:

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

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.

CAUTION:

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" on page 3-20.

6. 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" on page 3-18.

Installing the rear brake caliper

7. Check:

Brake pedal operation Soft or spongy feeling Bleed
the brake system.

Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-20.

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 ...

Removing the rear brake master cylinder

NOTE: Before removing the rear brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: Rear brake light switch coupler 2. Loosen: Rear brake light switc ...

Other materials:

Checking the speed sensor
1. Check: Speed sensor output voltage Out of specification → Replace. a. Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness end) as shown. Positive tester probe gray "1" Negative tester probe gray/black "2" b. Set the main switch to "ON". c. ...

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 fluid reservoir Cracks/ ...

Checking the thermostat
1. Check: Thermostat Does not open at 80.5-83.5 C (176.9-182.3 F) Replace. a. Suspend the thermostat "1" in a container "2" filled with water. b. Slowly heat the water "3". c. Place a thermometer "4" in the water. d. While stirring the water, observe the thermostat and th ...