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

Yamaha YZF-R125 Service Manual / Chassis / Front brake / Installing the front brake caliper

1. Install:

  • Brake caliper "1" (temporarily)
  • Copper washers "2"

  • Brake hose "3"
  • Brake hose union bolt "4"

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to "CABLE ROUTING" on page 2-33.
CAUTION:
  • Install the brake hose at a 17 angle to the front brake caliper as shown in the illustration.
  • While holding the brake hose, tighten the union bolt.

Installing the front brake caliper


2. Remove:

  • Brake caliper

3. Install:

  • Brake pad spring
  • Brake pads
  • Brake caliper
  • Brake hose holder

Refer to "REPLACING THE FRONT BRAKE PADS" on page 4-22.

4. Fill:

  • Brake master cylinder 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 master cylinder 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 front brake caliper


7. Check:

Brake lever operation Soft or spongy feeling → Bleed the brake system.

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

    Assembling the front 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 front brake master cylinder
    NOTE: Before removing the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: Front brake light switch 2. Remove: Brake hose union bolt Copp ...

    Other materials:

    Checking the valves and valve guides
    The following procedure applies to all of the valves and valve guides. 1. Measure: Valve-stem-to-valve-guide clearance Out of specification Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter "a" - Valve stem diameter "b" 2. Replace: ...

    Checking the steering head
    1. Wash: Bearings Bearing races 2. Check: Bearings Bearing races Damage/pitting →Replace. 3. Replace: Bearings Bearing races a. Remove the bearing races from the steering head pipe with a long rod "1" and hammer. b. Remove the bearing race from the lower bracket ...

    Adjusting the rear disc brake
    1. Check: Brake pedal position (distance "a" from the center of the rider footrest to the center of the brake pedal) Out of specification Adjust. 2. Adjust: Brake pedal position a. Loosen the locknut "1". b. Remove the cotter pin "2", washer "3", and pin "4". c. Turn t ...

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