Yamaha XV1700P, XV1700PC. Service Manual - part 14

4 - 33

CHAS

FRONT AND REAR BRAKES

EAS00586

REAR BRAKE MASTER CYLINDER

2

3

4

5

1

6

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

Order

Job/Part

Q’ty

Remarks

Removing the brake fluid reservoir

Remove the parts in the order listed. 

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

For installation, reverse the removal 
procedure.

4 - 34

CHAS

FRONT AND REAR BRAKES

13

9

10

11

1

3

2

4

5

8

7

6

12

T

 

R

.

.

30 Nm (3.0 m 

•

 

kg, 22 ft

 

•

 

Ib)

T

 

R

.

.

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

.

.

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

.

.

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

T

 

R

.

.

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

Removing the rear brake master 
cylinder 

Remove the parts in the order listed. 

1

Brake master cylinder cover

1

Refer to “REMOVING THE 
REAR BRAKE MASTER 
CYLINDER” and “ASSEM-
BLING AND INSTALLING 
THE REAR BRAKE MAS-
TER CYLINDER”.

2

Union bolt

1

3

Copper washer

2

4

Brake hose

1

Disconnect.

5

Brake master cylinder bracket

1

6

Rear brake light switch

1

7

Horn 1 connector

2

Disconnect.

8

Right footrest assembly (right)

1

4 - 35

CHAS

FRONT AND REAR BRAKES

13

9

10

11

1

3

2

4

5

8

7

6

12

T

 

R

.

.

30 Nm (3.0 m 

•

 

kg, 22 ft

 

•

 

Ib)

T

 

R

.

.

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

.

.

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

.

.

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

T

 

R

.

.

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

9

Cotter pin

1

10

Pin

1

11

Brake rod

1

12

Locknut

1

13

Brake master cylinder

1

For installation, reverse the removal 
procedure.

4 - 36

CHAS

FRONT AND REAR BRAKES

EAS00587

Order

Job/Part

Q’ty

Remarks

Disassembling the rear brake 
master cylinder 

Remove the parts in the order listed. 

1

Dust boot

1

2

Circlip

1

3

Brake master cylinder kit

1

4

Circlip

1

5

Brake hose joint

1

6

O-ring

1

7

Brake master cylinder

1

For assembly, reverse the disassembly 
procedure.

1

2

3

4

5

6

7

New

4 - 37

CHAS

FRONT AND REAR BRAKES

EAS00588

REMOVING THE FRONT BRAKE MASTER 
CYLINDER

NOTE:

_ 

Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system. 

1. Remove: 

• union bolt 

1

 

• copper washers 

2

 

• brake hose 

3

NOTE:

_ 

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

EAS00589

REMOVING THE REAR BRAKE MASTER 
CYLINDER

1. Remove: 

• union bolt 

1

 

• copper washers 

2

 

• brake hose 

3

NOTE:

_ 

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

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 

(brake master cylinder body) 
Obstruction 

→

 Blow out with compressed

air.

È

Front 

É

Rear

3

2

1

È

É

1

4 - 38

CHAS

FRONT AND REAR BRAKES

2. Check: 

• brake master cylinder kit 

Damage/scratches/wear 

→

 Replace.

È

Front 

É

Rear

È

É

3. Check: 

• rear brake fluid reservoir 

1

 

Cracks/damage 

→

 Replace. 

• rear brake fluid reservoir diaphragm 

2

 

Cracks/damage 

→

 Replace.

2

1

4. Check: 

• front brake master cylinder reservoir 

1

 

Cracks/damage 

→

 Replace. 

• front brake master cylinder reservoir dia-

phragm 

2

 

Damage/wear 

→

 Replace.

5. Check: 

• brake hoses 

Cracks/damage/wear 

→

 Replace.

EAS00598

ASSEMBLING AND INSTALLING THE 
FRONT BRAKE MASTER CYLINDER

WARNING

_ 

• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid. 

• Never use solvents on internal brake

components. 

Recommended brake fluid 

DOT 4

4 - 39

CHAS

FRONT AND REAR BRAKES

1. Install: 

• brake master cylinder 
• brake master cylinder holder 

1

NOTE:

_ 

• Install the brake master cylinder holder with

the “UP” mark facing up. 

• Align the end of the brake master cylinder

holder with the punch mark 

a

 on the handle-

bar. 

• First, tighten the upper bolt, then the lower

bolt. 

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

2. Install: 

• copper washers 

 

• brake hose 
• union bolt

WARNING

_ 

Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2. 

NOTE:

_ 

• While holding the brake hose, tighten the

union bolt as shown. 

• Turn the handlebar to the left and right to

make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary. 

New

T

 

R

.

.

32 Nm (3.2 m  •  kg, 23 ft  •  lb)

3. Fill: 

• brake master cylinder reservoir 

(with the specified amount of the recom-
mended brake fluid)

Recommended brake fluid 

DOT 4

4 - 40

CHAS

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 reser-
voir. 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. 

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.

FRONT AND REAR BRAKES

4 - 41

CHAS

EAS00608

ASSEMBLING AND INSTALLING THE 
REAR BRAKE MASTER CYLINDER

1. Install: 

• copper washers 

1

  

• brake hoses 

2

 

• union bolt 

3

 

WARNING

_ 

Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2. 

CAUTION:

_ 

When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection 

a

 onto brake

master cylinder bracket, as shown. 

a

2

1

3

New

New

T

 

R

.

.

30 Nm (3.0 m  •  kg, 22 ft  •  lb)

2. Fill: 

• brake fluid reservoir 

(to the maximum level mark)

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. 

Recommended brake fluid 

DOT 4

FRONT AND REAR BRAKES

4 - 42

CHAS

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.

a

5. Adjust: 

• brake pedal position 

a

 

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

6. Adjust: 

• rear brake light operation timing 

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

Brake pedal position (from the 
top of the rider footrest to the top 
of the brake pedal) 

80 mm (3.2 in)

FRONT AND REAR BRAKES

4 - 43

CHAS

EAS00613

FRONT BRAKE CALIPERS

3

2

1

5

4

4

T

 

R

.

.

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

T

 

R

.

.

32 Nm (3.2 m 

•

 

kg, 23 ft

 

•

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

Removing the front brake calipers 

Remove the parts in the order listed. 
The following procedure applies to both
of the front brake calipers.

Brake hose holder

Refer  to  “FRONT WHEEL AND BRAKE
DISCS”.

Brake fluid

Drain.

1

Union bolt

1

Refer to “DISASSEM-
BLING THE FRONT 
BRAKE CALIPERS” and 
“ASSEMBLING AND 
INSTALLING THE FRONT 
BRAKE CALIPERS”.

2

Copper washer

2

3

Brake hose

1

Disconnect.

4

Brake caliper bolt

2

5

Brake caliper

1

For installation, reverse the removal 
procedure.

FRONT AND REAR BRAKES

4 - 44

CHAS

EAS00615

7

6

7

8

7

4

6

4

7

5

3

2

1

5

New

New

New

New

T

 

R

.

.

6 Nm (0.6 m

 

•

 

kg, 4.3 ft

 

•

 

Ib)

Order

Job/Part

Q’ty

Remarks

Disassembling the front brake 
calipers 

Remove the parts in the order listed. 

The following procedure applies to both
of the front brake calipers. 

1

 

Brake pad clip

2

2

 

Brake pad pin

1

3

 

Brake pad spring

1

4

 Brake 

pad

2

5

 

Brake pad shim

2

6

 

Brake caliper piston

4

Refer to “DISASSEMBLING THE FRONT 
BRAKE CALIPERS”.

7

 

Brake caliper piston seal

8

8

 Bleed 

screw

1

For assembly, reverse the disassembly 
procedure.

FRONT AND REAR BRAKES

4 - 45

CHAS

EAS00616

REAR BRAKE CALIPER

5

4

4

3

1

2

T

 

R

.

.

27 Nm (2.7 m 

•

 

kg, 19 ft

 

•

 

Ib)

T

 

R

.

.

30 Nm (3.0 m 

•

 

kg, 22 ft

 

•

 

Ib)

8

6

7

8

7

New

Order

Job/Part

Q’ty

Remarks

Removing the rear brake caliper 

Remove the parts in the order listed. 

1

Union bolt

1

Refer to “DISASSEM-
BLING THE REAR BRAKE 
CALIPER” and “ASSEM-
BLING AND INSTALLING 
THE REAR BRAKE CALI-
PER”.

2

Copper washer

2

3

Brake hose

1

Disconnect.

4

Brake caliper retaining bolt

2

5

Brake caliper

1

6

Brake  pad

2

7

Brake pad shim

2

8

Brake pad spring

2

For installation, reverse the removal 
procedure.

FRONT AND REAR BRAKES

4 - 46

CHAS

EAS00617

3

2

1

T

 

R

.

.

6 Nm (0.6 m

 

•

 

kg, 4.3 ft

 

•

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

Disassembling the rear brake 
caliper 

Remove the parts in the order listed. 

1

 

Brake caliper piston

1

Refer to “DISASSEMBLING THE REAR 
BRAKE CALIPER”.

2

 

Brake caliper piston seal

2

3

 Bleed 

screw

1

For assembly, reverse the disassembly 
procedure.

FRONT AND REAR BRAKES

4 - 47

CHAS

EAS00625

DISASSEMBLING THE FRONT BRAKE 
CALIPERS

The following procedure applies to both of the
brake calipers.

NOTE:

_ 

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

1. Remove: 

• union bolt 

1

 

• copper washers 

2

 

• brake hose

NOTE:

_ 

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. Secure the right side brake caliper pistons

with a piece of wood 

a

. 

b. Blow compressed air into the brake hose

joint opening 

b

 to force out the left side pis-

tons from the brake caliper.

WARNING

_ 

• Never try to pry out the brake caliper pis-

tons. 

• Do not loosen the bolts 

3

. 

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

right side pistons from the brake caliper. 

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

FRONT AND REAR BRAKES

4 - 48

CHAS

EAS00627

DISASSEMBLING THE REAR BRAKE 
CALIPER

NOTE:

_ 

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

1. Remove: 

• union bolt 

1

 

• copper washers 

2

 

• brake hose 

3

NOTE:

_ 

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

2

1

3

2. Remove: 

• brake caliper piston
• brake caliper piston seals 

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Blow compressed air into the brake hose

joint opening 

a

 to force out the pistons

from the brake caliper.

WARNING

_ 

• Cover the brake caliper piston with a rag.

Be careful not to get injured when the pis-
tons are expelled from the brake caliper. 

• Never try to pry out the brake caliper pis-

tons. 

b. Remove the brake caliper piston seals. 

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

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a

FRONT AND REAR BRAKES