2002 YAMAHA YFM660R brake

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
NOTE:

Recommended brake fluid: DOT4


Brake fluid replacement:
1. When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake
fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Clutch*•Check operation.
•Adjust if necessary.Wheels*•Check balance/damage/runout.
•Replace if necessary.Wheel bearings*•Check bearing assembly for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.Upper and lower arm
pivot and steering
shaft*•Lubricate every 6 months.**Rear arm pivot*•Lubricate every 6 months.**Fittings and fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5LP61.book Page 8 Monday, August 27, 2001 3:49 PM

8-59 1. Wear indicator groove
1. Rainure d’indicateur d’usure
1. Ranura indicador de desgaste
Front
Avant
Delantero1. Wear indicator groove
1. Rainure d’indicateur d’usure
1. Ranura indicador de desgasteRear
Arrière
Trasero
EBU01027
Front and rear brake pad inspection
Each brake pad is provided with a wear indicator
groove. The indicators allow checking of brake
pad wear without disassembling the brake. Apply
the brake and inspect the wear indicator grooves.
If the pad is worn to the point that the wear indica-
tor grooves are almost in contact with the disc
plate, ask a Yamaha dealer to replace the pads.
U5LP61.book Page 59 Monday, August 27, 2001 3:49 PM

8-61 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
Front
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo Rear
Arrière
Trasero
EBU01017*
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the lower level and replenish when necessary.NOTE:_ To access the rear brake fluid reservoir, remove
the reservoir cover by removing the bolts. (See
page 8-63.)_
U5LP61.book Page 61 Monday, August 27, 2001 3:49 PM

8-63 1. Brake fluid reservoir cover
2. Bolt (× 2)
1. Couvercle du réservoir de liquide de frein
2. Boulon (× 2)
1. Cubierta del depósito de líquido de frenos
2. Perno (× 2)
Rear
Arrière
Trasero
Observe these precautions:

When checking the fluid level, make sure the
top of the brake fluid reservoir is level.


Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.


Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor brake performance.


Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.


Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid: DOT 4
U5LP61.book Page 63 Monday, August 27, 2001 3:49 PM

8-65
EBU00820
Brake fluid replacement
1. Complete fluid replacement should be done
only by trained Yamaha service personnel.
2. Have a Yamaha dealer replace the following
components during periodic maintenance or
when they are damaged or leaking.

Replace all rubber seals every two years.


Replace all hoses every four years.WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U5LP61.book Page 65 Monday, August 27, 2001 3:49 PM

8-67 a. Free play
a. Jeu
a. Juego libre
EBU00681
Front brake adjustment
The front brake lever should have a free play of
zero mm at the lever end. If not, ask a Yamaha
dealer to adjust it.
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U5LP61.book Page 67 Monday, August 27, 2001 3:49 PM

8-69 a. Brake pedal position
a. Position de la pédale de frein
a. Posición del pedal del freno
EBU00952
Rear brake adjustment
Pedal height adjustmentThe top of the brake pedal should be positioned
4 mm below the top of the footboard. If not, ask a
Yamaha dealer to adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the brake pedal position is cor-
rect.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5LP61.book Page 69 Monday, August 27, 2001 3:49 PM

8-71 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Locknut 2. Adjusting bolt
a. Cable length
1. Contre-écrou 2. Boulon de réglage
a. Longueur de câble
1. Contratuerca 2. Perno de ajuste
a. Longitud del cable
EBU00953
Parking brake adjustment
Parking brake adjustment may be required if the
parking brake does not hold properly.
1. Fully loosen the parking brake cable adjust-
ing bolt locknut and the adjusting bolt on the
clutch lever.
2. Loosen the adjusting bolt locknut and the ad-
justing bolt on the rear brake caliper.
3. Turn the adjusting bolt on the clutch lever so
that cable length
a is 64 ~ 68 mm.NOTE:If the cable cannot be adjusted to specification,
consult a Yamaha dealer. _4. Tighten the adjusting bolt locknut on the
clutch lever.
U5LP61.book Page 71 Monday, August 27, 2001 3:49 PM