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:

    Installing the cylinder head
    1. Install: Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 2. Tighten: Cylinder head bolts "1" Cylinder head bolts "2" NOTE: Lubricate the cylinder head bolts and washers with engine oil. Tighten the cylinder head bolts in the proper tighten ...

    Checking the shift shaft
    1. Check: Shift shaft Bends/damage/wear Replace. Shift shaft spring Damage/wear Replace. Checking the stopper lever 1. Check: Stopper lever Bends/damage Replace. Roller turns roughly Replace the stopper lever. Stopper lever spring Damage/wear Replace. ...

    Checking the spark plug
    1. Remove: Right side cover Refer to "GENERAL CHASSIS" on page 4-1. 2. Disconnect: Spark plug cap 3. Remove: Spark plug CAUTION:Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling ...

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