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XS360 (1976-1982)
Инструкция по эксплуатации Страница: 32

Yamaha XS360 (1976-1982) [32/34] Yamaha xs360 400

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Yamaha XS360 400 3 Check the piston and cylinder bore for scoring and wear and replace the compo nents if damage of this sort is noted 4 Check the cylinder cups for cracking and dry rotting and replace them if this con dition is present Assembly 1 Soak the cups in new brake fluid for a time before assembly 2 Use the special cylinder cup installer when fitting the cup to the piston 3 Install the stopper plate into the master cylinder Insert the spring and valve 4 Insert the piston into the master cylin der Take care not to scratch the piston or cylinder wall Fit the snap ring Be sure that it is firmly seated 5 Fit the boot into the grooves of the mas ter cylinder and piston ceptable lining thickness is 2 mm 0 08 in New linings will have a thickness of 4 mm 0 16 in 4 Remove the shoes from the brake plate by folding them in towards the center 5 Check the condition of the brake return springs Standard free length of the springs is 68 mm 2 68 in and they should be re placed if they are stretched over this stan dard Also check the springs for rust dam aged ends or other obvious signs of age 6 Measure the diameter of the brake drum in at least two directions Standard di ameter is 180 mm 7 1 in If the measured diameter exceeds this standard by more than a small amount the drum should be re placed 7 Rough up the surface of the brake drum ring Take out the cap and fork spring Drain off the fork oil 2 Remove the alien bolt from the bottom of the fork slider 3 Separate the fork slider from the fork tube 4 Remove the clip from the bottom of the fork tube and remove the piston assembly 5 To remove the slider oil seal remove the dust cover and the snap ring and pry the old seal out New seals must always be used on assembly Installation Bolt the master cylinder to the haldlebar Connect the brake and tighten the banjo bolt to 17 20 ft lbs Fill the master cylinder with fresh brake fluid and bleed the system Upper triple clamp pinch bolts DISC SERVICE The brake disc normally requires no service of any kind However if the disc becomes scored for any reason it should be replaced and a new set of pads should be installed A badly scored disc will reduce the effec tiveness of the brake and shorten pad life considerably If the front brake lever os cillates or fluctuates when the brake is ap plied at speed the indication is that the brake disc is warped or bent Check the run out of the disc with a dial indicator and re place it if run out exceeds 0 15 mm 0 006 in Measure disc thickness If it is less than 4 5 mm 0 18 in it should be replaced To replace the disc 1 Remove the wheel 2 Bend back the locktabs unscrew the bolts and remove the disc from the hub 3 Mount the new disc on the hub and tighten the bolts evenly using new locktabs or thread locking compound to secure them Proper torque is 12 16 ft lbs 4 Examine the brake pads and replace them if they are close to the limit of wear or have worn in an unusual pattern Rear Disc Brake Inspection with sandpaper Clean the drum out thoroughly before assembly 8 Check for excessive play in the brake rod linkage If play exists the most obvious cause is wear wear of the clevis pins Replace the pins as necessary 9 The brake cams can be removed from the brake plate after removing the shoes and brake linkage Mark the brake levers and cams before disassembly so the levers can be reinstalled in their original positions Clean the cams in solvent Remove any rust or cor rosion with medium grade emery cloth Check that the cams can rotate freely in their holes Check the condition of the splines Replace any bent or otherwise damaged cams Before installation smear the cams with a good grade of chassis grease Rear Drum Brake Removing a fork slider oil seal Service procedures for the rear drum single leading shoe brake are similar to those for the front drum brake described above The only difference is the brake drum diameter which is 160 mm 6 3 in for the rear brake The rear disc brake components are virtually identical to those for the front system except for the method of mounting To remove the rear caliper disconnect the brake line from the caliper unbolt the brake FRONT FORKS anchor and remove the rear axle For all service procedures refer to the Removal Front Disc Brake section above 1 Remove the front wheel and fender 2 On disc brake models unbolt the cali Front Drum Brake per from the fork slider Disconnect the 1 Remove the front wheel from the ma brake line from the fork leg 3 Loosen the upper and lower triple chine Take out the brake plate 2 Check the linings for scoring a glazed clamp pinch bolts Pull each fork leg down surface or other unusual wear Scored lin and free of the triple clamps ings should be replaced If the linings are only glazed they can be roughed up with sandpaper Be sure to clean them thoroughly Dissassembly after this operation 1 Remove the rubber fork caps press 3 Measure lining thickness at the middle and ends of each brake shoe Minimum ac down on the metal caps and remove the snap 1294 1 Inspect the fork tubs for bends such as might have been incurred in an accident Re placement is recommended rather than at tempting to straighten bend fork tubes 2 The chrome plating on the fork tubes must be in perfect condition in the area along which the slider oil seal rides If the plating is chipped or flaking the seal will leak Dam Fork components age to the plating requires replacement of the fork tube 3 Compare the spring heights of the fork springs from each fork leg They should be equal Standard spring free length is 484 mm 19 1 in If the spring heights are unequal or if either or both of them has been com pressed through use both should be re placed

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