Snowmobile Yamaha Phazer PZ50 (2007-2008 year). Instruction - part 35

 

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Snowmobile Yamaha Phazer PZ50 (2007-2008 year). Instruction - part 35

 

 

4-35

POWR

TR

BRAKE

Order

Job name/Part name

Q’ty

Remarks

Brake caliper and parking brake 
removal

Remove the parts in the order listed below.

Brake fluid

Drain.

1

Brake hose

1

2

Retaining pin

2

3

Brake pad

2

4

Pad spring

1

5

Brake caliper bracket

1

6

Brake caliper

1

7

Brake caliper piston

2

8

Brake caliper piston seal

4

9

Parking brake cable

1

10

Spring

1

11

Parking brake assembly

1

For installation, reverse the removal proce-
dure.

9

11

10

3

2

4

8

8

7

7

5

1

6

New

New

É

Ê

Ë

È

Ì

Ì

16 Nm (1.6 m 

 kg, 12 ft 

 lb)

10 Nm (1.0 m 

 kg, 7.2 ft 

 lb)

48 Nm (4.8 m 

 kg, 35 ft 

 lb)

30 Nm (3.0 m 

 kg, 22 ft 

 lb)

É:   

6 Nm (0.6 m 

 kg, 4.3 ft 

 lb)

È:   

Ê:   
Ë:   
Ì:   

: 1 Silicone grease

4-36

POWR

TR

BRAKE

BRAKE CALIPER DISASSEMBLY

NOTE:

Before disassembling a caliper, drain brake fluid
from brake hose, master cylinder, brake caliper and
brake reservoir of their brake fluid.

1. Remove:

• Pistons
• Piston seals

Removal steps:

• Using a wood of piece, lock the piston.
• Blow compressed air into the hose joint opening

a to force out the pistons from the caliper body.

WARNING

Never try to pry out the pistons.

a

BRAKE CALIPER INSPECTION AND 
REPAIR

WARNING

All internal brake components should be
cleaned only with new brake fluid. Do not use
solvents as they will cause seals to swell and
distort.

Recommended brake component 

replacement schedule

Brake pads

As required

Piston seals

Every two years

Brake hose

Every four years

Brake fluid

Only when brakes are 
disassembled.

4-37

POWR

TR

BRAKE

1. Inspect:

• Caliper piston

Scratches/rust/wear 

→ Replace the caliper 

assembly.

• Caliper cylinder

Wear/scratches 

→ Replace the caliper

assembly.

• Caliper body

Cracks/damage 

→ Replace.

• Oil delivery passage (caliper body)

Blow out with compressed air.

WARNING

Replace the piston seals and dust seals when-
ever a caliper is disassembled.

BRAKE CALIPER ASSEMBLY

WARNING

• All internal parts should be cleaned only with

new brake fluid.

• Internal parts should be lubricated with brake

fluid when installed.

• Replace the piston seals whenever a caliper is

disassembled.

Recommended brake fluid:

DOT 4

BRAKE CALIPER INSTALLATION

1. Install:

• Brake hose 1 

CAUTION:

When installing the brake hose 1 onto the
brake caliper 
2, make sure that the brake pipe
touches the projection 

a on the brake caliper.

T

 

R

.

.

Union bolt (brake hose):

30 Nm (3.0 m · kg, 22 ft · lb)

1

2

a

4-38

POWR

TR

BRAKE

Order

Job name/Part name

Q’ty

Remarks

Brake master cylinder removal

Remove the parts in the order listed below.

Brake fluid

Drain.

Left handlebar switch

Refer to “STEERING” in CHAPTER 3.

1

Brake light switch

1

2

Brake  lever

1

3

Brake hose

1

4

Holder

1

5

Parking brake cable

1

Disconnect.

6

Parking brake lever

1

7

Master cylinder assembly

1

For installation, reverse the removal proce-
dure.

Brake master cylinder disassembly

Remove the parts in the order listed below.

Reservoir cap set

1

2 Diaphragm

1

3 Master 

cylinder 

kit

1

4 Master 

cylinder 

body

1

For assembly, reverse the disassembly pro-
cedure.

 

 

 

 

 

 

 

Content   ..  33  34  35  36   ..