Removing brake pads and caliper
 

HI there,

I am about to replace the rear brake pads on my Ten since they are knackered.
I had a look to my Haynes manual but I would like to clarify a couple of things before proceeding.


1) Only one of the brake pads is wasted (the one sitting on the cylinder). Is this normal?

2) Do I need to buy a tool like this to take the pads retaining pin?
http://www.amazon.co.uk/Silverline-P.../dp/B000LFVNNM
Do I use gently the hammer to the the pin in and out?

3) I read that I should put some copperslip on the retaining pin before putting it back? THe brake pad is Ferodo brand and it has already this blue compound on the back and edges of the brake pad.

4) How do I disassemble the caliper from the swingarm mounting bracket? In the Haynes manual it says "slide it out"... no need to unscrew anything, just push away?
I probably dont need to dissamsemble the bracket from caliper, but I wanted to properly clean the caliper and put some copperslip on the pins.



Thanks and sorry for asking so many questions :typing[1]:

hi mate, i have mine off at the moment so here goes
i have the rear wheel out at the moment so once thats out caliper simply slides off its sliding pins the ones with the little rubber boots on them, pull out the little clip holding the brake pad pin in and then give the pin a little tap through the hole on the right hand side as it has a little expanding clip on the left hand end of it, once thats out both pads will fall out. give everything a good clean and i tend to put a little bit of copper slip where ever the pads touch the caliper.
not sure if you can do this with the wheel still in as i didnt look as my wheel is already out i thought i would clean caliper.

Got the pin out so that pads are now off the caliper.

Problem is that the caliper will not come off the bracket. I reckon the sliding pins must have seized. Any suggestions on how to slide the bracket out? I put a bit of wd40 but the "rubber boots" will not allow much in :eusa_wall:

Also, here is a picture of the old pads. You can see the difference in use between the two (I know, I should have changed the pads before :eusa_wall: )

http://imageshack.us/scaled/medium/841/o7fx.jpg

Cheers

yep sounds like you caliper is siezed mate which is why your pads are like that, good luck sorting it out they can be a *******! you might have to disconect the caliper from the brake line and do it in a vice or you could try gently taping the bracket off the caliper with a rubber/hide malet or maybe a bit of leverage between caliper and bracket.....good luck

I sorted out a previous bike with the same seized rear piston and caliper slide.

To fix the piston you need to pump the pedal so the piston becomes exposed enough before coming right out (and making a right mess) then use fine grade sand paper to smooth out the ridges along the piston that would have built up. Working the piston in and out should free it up. I use a pair of pipe pliers to get a difficult piston back in (wider jaws).

The slides can be the same but use plenty of grease during reassembly. Could be caused by water ingress due to damaged rubber boots? A �5 fix.

Rear calipers get hammered as it's more difficult to access to strip and clean reguarly.

Hi,
Piston looks fine. Looks like is the sliding pins that probably got corroded and hence the caliper is stuck.
This seems now like a bigger job than replacing the brake pads was :cry[1]:
Good that I realised about the problem though :)

Thanks

I already try to apply some leverage between the caliper and the bracket with a big screw driver, but didnt want to push much to not bend the sliding pins. Will try to put some more wd40 in the pins.

Thanks

most lightly it's going to be the front pin thats seized..
The rear pin fits in a rubber sleeve...
On the front pin pull the little rubber boot/seal off "it's toast anyway
& will need replaceing" Then get a spanner & see if you can turn the pin
to brake it free... It should be screwed into the caliper..
Replace both rubbers...

Thanks. Will give a try.
Is this rubber boot/sleeve specific for the Yamaha/Brembo calipers? Or can I get a general purpose one?

Thanks

I would think it would be easier to get new pins and rubber boots from yamaha

I would get the rubbers boots/seals from yamaha... They are cheap...
Look on E-bay or OTR .. someone might make stainless steel pins..

�5 fix :smilies0943: The 0 button on your keyboard must be broken! ;)

I had to fit new boots on the sliders (as one had a split) when I last changed my rear pads a few months back - they were just shy of �50 from the dealer. Fifty quid for two small bits of rubber! Searched high and low for pattern items to no avail.

Apart from pads, spring clip, boots and pad retaining pin, there is nothing else available to rebuild the caliper. Seals, piston, sliding pins are not available as spares!

Oh yeah... and a new caliper is �350! :Christo_pull_hair:

50 pound ?.... They fair get into you fella's

Pleiades is right. I sent an email yesterday to Metropolis Yamaha dealer asking for a price for the 5DSF591700 part, which is the rubber boot:

http://imagizer.imageshack.us/v2/640...0/268/1up0.png

The price is:
5DSF59170000 SOUFFLET, ETRIER 37.820 +VAT :wtfk::wtfk:

For some reason they gave me the price of the little piece pin pad piece (5VKF592410 in the pic) and it costs 11,5 pounds! What a rip!



Time to search for an alternative... :thumbsdown:
Pleaides, are you sure you looked well out there?? :D

P.S. Seems like the sliding pins are not a separated part? THe catalogue does not show the part number.

I cant remember what I paid when I needed one of those little rubber boots about 6 months ago but it was nowhere near �37+VAT. I did think it was a lot for what it was but something around a tenner is in my mind.

Let me know if you remember where you found then :D :ebay:

I searched high and low, in the UK and overseas, to no avail. I even looked at other bikes that use the same caliper too, from Aprilia through to Triumph... and nothing came up!

Having said the above, I thought I'd have another go at searching out an alternative and would you believe it, I found a cheaper source... and it's from BMW!:smilies0349:

Rear caliper rubber boot repair kit BRA30312 for the F650/700/800GS rear caliper, which is the same as the Tenere item (abeit with a slightly different mounting bracket and in black).

Available here (sixth item down) for �19.42 - not exactly cheap, but half the price of the Yamaha parts.

Great finding Pleiades. How did you check that the Brembo caliper from the Ten is the same?

I also looked at these rubber boots for the XTZ660'98 on Ebay:

http://cgi.ebay.co.uk/ws/eBayISAPI.d...:X:RTQ:GB:1123

http://www.ebay.co.uk/itm/Yamaha-XTZ...item54009b8adf


They look very similar to the ones from the Ten, although I double checked and the part number is not the same. I asked the shop and they cannot tell whether it will fit the Brembo brakes on the Ten.

Looks like the BMW's are a safer bet.

Visual inspection of a mate's bike. Then I had a look at the obvious thing first - pads, and indeed both the F800GS and the XT660Z take the same pads: Brembo (07BB02), EBC (FA208). After that I cross referenced the rest of the stuff: Pad retaining pin, spring clip and boots, and all match up. Interestingly you can get a replacement piston seal kit from BMW, but not from Yamaha, which is worth remembering for future reference.

Reckon you're right. Not sure how long the ebay rubber would last? Those boots could have been held in stock since 1998, so they may well be past their best?

"Ebay:

http://cgi.ebay.co.uk/ws/eBayISAPI.d...:X:RTQ:GB:1123"

Fixed for a fiver!

Phew.

Can you double check the link? seems like it doesnt work.

Hi,

just to confirm that the Caliper rubber cover repair kit | BRA30312 from motorWorks fitted perfectly on the rear brake caliper of my Ten. Thanks Pleiades for the suggestion.

The sliding pin was really stuck. Have to push/hit with a bar extender and a hummer close to the base of the sliding pin to separate the caliper from the bracket. The bracket hold onto a vise.

Cheers

Thanks for your help.

Is it the same for the front brakes?
I inquired yamaha dealer for those rubber boots and price is 58� for each pair!!! WTF ???
I told him i will use the older ones and put grease more freaquently :)

Rear caliper repair kit cross-references with BMW F650/700/800 twin.

For front caliper rebuild parts, including the piston seal kit (not available from Yamaha), refer to BMW G650GS single cylinder bikes. This BMW (Brembo) caliper is the same as that fitted to the XTR and XTZ front, although you'll need two of everything on the Z!

Click here for the parts.

FYI the BMW F-series twins have a very similar looking caliper to ours, but crucially it has bigger pistons and takes a larger pad.

I just bought a pair to do one front calliper from my Yamaha dealer for �6. The BMW ones listed in the above threads work out at �25.36 per pair.

The bags are not Yamaha but have Nissin written on them. The reference numbers are NC-B1 (for the long one)and NC-B2 for the other.

Also written on the bags are 'Please refer to Nissin Catalogue for applications"


Hope this helps to stop others getting right royally ripped off for such a small and obviously cheap to make part....

:)


.

€6 a pair - wow! You'll have to tell us who your dealer is? ;)

When I enquired at my local dealer they wanted �14.38 each for just the pin, never mind the R-clips etc.

Claudet Moto Pau.


Drill an old nail and put a split pin through it...just wouldn't have that 'Factory Look' lol


:)


.

Removing brake pads and caliper
 

I know where you're coming from. That's how the bottom shock bushes are held in place on by Land Rover - 4" nail twa*ted with a hammer! Agricultural engineering. Some how it wouldn't feel right on the Z! ;)

Alternate calliper boots and brake pads for XT660Z Tenere
 

Disgusted with the price that Yamaha (Australia) wanted for a couple of small bits of rubber I looked for alternatives and found that the Brembo calliper boots are the same as used by KTM on the EXC, 690R (front) and 690R, 990 Adventure (rear), not surprising really as the boots are a Brembo supplied part. A full single calliper boot refurb kit from my local KTM deal only cost $12 (Aud), and unlike Yamaha they were a regular stocked item.

Pad compound aside the brake pads are also compatible between these bikes, In the past I have replaced the front pads on my XT660Z with pads from my spares kit that were intended for the front of my KTM exc300 (2007 model).

Hope this helps.