Yamaha XVS1100 (L). Service Manual - part 15

 

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Yamaha XVS1100 (L). Service Manual - part 15

 

 

6-23

Order

Job name / Part name

Q’ty

Remarks

Disassembling the front brake
master cylinder
Dust boot
Circlip
Master cylinder cup
Spring

1
1
1
1

Remove the parts in the order listed.

For assembly, reverse the disassembly
procedure.

1
2
3
4

FRONT AND REAR BRAKES

CHAS

6-24

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8
9

10

Removing the rear brake master
cylinder
Brake fluid
Brake switch connector
Cotter pin / washer
Pin
Bolts
Brake pedal assembly
Union bolt
Copper washers / brake hose
Clips/ reservoir hose
Master cylinder assembly
Reservoir tank

1

1 / 1

1
2
1
1

2/ 1
2/ 1

1
1

Remove the parts in the order listed.

Drain
Disconnect

For installation, reverse removal
procedure.

Refer to “REMOVING / INSTALLING THE
REAR BRAKE MASTER CYLINDER”.

64 Nm (6.4 m

kg)

30 Nm (3.0 m

kg)

23 Nm (2.3 m

kg)

FRONT AND REAR BRAKES

CHAS

EAS00586

REAR BRAKE MASTER CYLINDER

6-25

Order

Job name / Part name

Q’ty

Remarks

Disassembling the rear brake master
cylinder
Master cylinder boot
Circlip
Master cylinder cup
Spring

1
1
1
1

Disassembly the parts in the order listed.

For assembly, reverse the disassembly
procedure.

1
2
3
4

FRONT AND REAR BRAKES

CHAS

6-26

FRONT AND REAR BRAKES

CHAS

NOTE:

NOTE:

NOTE:

NOTE:

EAS00588

REMOVING THE FRONT BRAKE MASTER
CYLINDER

Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.

1. Remove:

rear view mirror (right)

brake lever / compression spring

brake switch 

1

2. Remove:

union bolt 

2

copper washers

brake hose 

3

To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.

3. Remove:

master cylinder bracket

master cylinder

EAS00589

REMOVING THE REAR BRAKE MASTER
CYLINDER

Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.

1. Remove:

brake switch connector

cotter pin / washer

pin

bolt / brake pedal assembly

2. 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.

3. Remove:

clips / reservoir hose

master cylinder assembly

6-27

A

B

A

B

A

B

FRONT AND REAR BRAKES

CHAS

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 

2

(brake master cylinder body)
Obstruction 

 Blow out with compressed air.

A Front

B Rear

2. Check:

brake master cylinder kit 

1

Damage / scratches / wear 

 Replace.

A Front

B Rear

3. Check:

brake fluid reservoir 

1

Cracks / damage 

 Replace.

brake fluid reservoir diaphragm 

2

Cracks / damage 

 Replace.

A Front

B Rear

4. Check:

brake hoses 

1

Cracks / damage / wear 

 Replace.

6-28

FRONT AND REAR BRAKES

CHAS

WARNING

10 Nm (1.0 m

kg)

NOTE:

30 Nm (3.0 m

kg)

WARNING

NOTE:

EAS00598

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:

brake master cylinder 

1

brake master cylinder bracket 

2

Install the brake master cylinder bracket with
the “UP” mark facing up.

Align the end of the brake master cylinder hold-
er with the punch mark 

a

 on the handlebar.

First, tighten the upper bolt, then the lower bolt.

2. Install:

copper washers (New) 

1

brake hose 

2

union bolt 

3

Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.

While holding the brake hose, tighten the
union bolt as shown.

Turn the handlebar to the left and to the right to
make sure that 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

6-29

FRONT AND REAR BRAKES

CHAS

WARNING

CAUTION:

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 reservoir. Water will signifi-
cantly lower the boiling 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.

6-30

FRONT AND REAR BRAKES

CHAS

WARNING

CAUTION:

WARNING

CAUTION:

EAS00610

INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:

copper washers (New)

brake hose

Union bolt

30 Nm (3.0 m

kg)

Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.

When installing the brake hose onto the brake
master cylinder make sure that the brake pipe
touches the projections 

a

 as shown.

2. Fill:

brake fluid reservoir
(to the maximum level mark)

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 performance.

When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling 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.

3. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4. 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.

6-31

FRONT AND REAR BRAKES

CHAS

5. Adjust:

brake pedal position 

a

Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.

Brake pedal position (below the
top of the rider footrest)

81.8 mm

6. Adjust:

rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.

6-32

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6

Removing the front brake calipers
Brake fluid
Brake hose holder
Union bolt
Copper washers
Brake hose
Retaining bolt
Brake caliper assembly

1
1
2
1
1
1

Remove the parts in the order listed.
Drain

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTALLING
THE FRONT BRAKE CALIPERS”.

30 Nm (3.0 m

kg)

23 Nm (2.3 m

kg)

6 Nm (0.6 m

kg)

FRONT AND REAR BRAKES

CHAS

FRONT BRAKE CALIPERS

6-33

Order

Job name / Part name

Q’ty

Remarks

Disassembling the front brake
calipers
Pad spring
Brake caliper pistons
Dust seals
Caliper piston seals
Bleed screw

1
2
2
2
1

Remove the parts in the order listed.

For assembly, reverse the disassembly
procedure.

Refer to “REMOVING THE FRONT
BRAKE CALIPERS”.

1
2
3
4
5

FRONT AND REAR BRAKES

CHAS

6-34

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5

Removing the rear brake caliper
Muffler
Muffler stay
Brake fluid
Brake hose holder
Union bolt
Copper washers
Brake hose
Caliper ass’y

1
1
2
1
1

Remove the parts in the order listed.

Drain

For installation, reverse the removal
procedure.

Refer to “REMOVING / INSTALLING
THE REAR BRAKE CALIPER”.

Refer to “REAR WHEEL AND BRAKE
DISC”.

40 Nm (4.0 m

kg)

30 Nm (3.0 m

kg)

FRONT AND REAR BRAKES

CHAS

ESA00616

REAR BRAKE CALIPER

6-35

Order

Job name / Part name

Q’ty

Remarks

Disassembling the rear brake caliper
Cover
Clips
Pad pins
Pad spring
Brake pads
Caliper pistons
Dust seals
Piston seals
Bleed screw

1
2
2
1
2
2
2
2
1

Disassembly the parts in the order listed.

For assembly, reverse the disassembly
procedure.

Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER”.

1
2
3
4
5
6
7
8
9

FRONT AND REAR BRAKES

CHAS

6-36

FRONT AND REAR BRAKES

CHAS

NOTE:

NOTE:

WARNING

NOTE:

EAS00624

REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.

Before removing either brake caliper, drain the
brake fluid from the entire brake system.

1. Remove:

brake hose holder

union bolt 

1

copper washers 

2

brake hose

Put the end of the brake hose into a container
and pump out the brake fluid carefully.

2. Remove:

brake caliper pistons 

1

brake caliper piston seals 

2

a. Blow compressed air into the brake hose

joint opening to force out the pistons from the
brake caliper.

Cover the brake caliper piston with a rag.
Be carful not to get injured when the piston
is expelled from the brake caliper cylinder.

Never try to pry out the brake caliper pis-
tons.

b. Remove the brake caliper piston seals.

EAS00628

REMOVING THE REAR BRAKE CALIPER

Before removing the brake caliper, drain the
brake fluid from the entire brake system.

6-37

FRONT AND REAR BRAKES

CHAS

NOTE:

WARNING

1. Remove:

union bolt 

1

copper wachers 

2

brake hose

Put the end of the brake hose into a container
and pump out the brake fluid carefully.

2. Remove:

brake caliper pistons 

1

brake caliper pistons seals 

2

a. Secure the right side brake caliper piston

with a piece of wood 

a

.

b. Blow compressed air into the brake hose

joint opening 

b

 to force out the left side pis-

ton from the brake caliper.

Never try to pry out the brake caliper pis-
tons.

Do not loosen the bolts.

c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the

right side piston from the brake caliper.

EAS00633

CHECKING THE FRONT AND REAR BRAKE
CALIPERS

Recommended brake component

replacement schedule:

Brake pads

If necessary

Piston seals

Every two years

Brake hoses

Every two years

Brake fluid

Every two years and
whenever the brake
is disassembled.

6-38

B

A

FRONT AND REAR BRAKES

CHAS

WARNING

WARNING

1. Check:

brake caliper pistons 

1

Rust / scratches / wear 

 Replace the brake

caliper piston assembly.

brake caliper cylinders 

2

Scratches / wear 

 Replace the brake cali-

per.

brake calipers 

3

Cracks / damage 

 Replace.

brake fluid delivery passages
(brake caliper body)
Obstruction 

 Blow out with compressed air.

Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.

A Front

B Rear

2. Check:

brake caliper brackets
Cracks / damage 

 Replace.

EAS00638

INSTALLING THE FRONT BRAKE CAL-
IPERS
The following procedure applies to both of the
brake calipers.

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 as they will cause the piston seals
to swell and distort.

Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.

Recommended brake fluid

DOT 4

 

 

 

 

 

 

 

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