XT660Z front caliper "non serviceable item"??
 

My XT660Z was stored for 2 months, front right caliper (Brembo) seized on. Piston would not return even using a C-clamp. Usual process then is remove pistons, new seals, new fluid, bleed system.

However, bikes dealers do not have a part number for seals because Yamaha say it is a non serviceable item (!!!) What the....? Needs a new caliper at a whopping 209 GBP. Luckily they agreed to do it under warranty (bike booked in for June when I return to UK).

Anyone else have problems like this? Is there a way of self servicing these calipers (ie is the seal kit available as if buying for a different model? cos I need to get some spares)

Trip to central Asia planned... don't expect to find too many friendly neighbourhood Yamaha dealers in the Turkmeni scrub lands!!

I've just had a look at the owners manual and it mentions replacing the internal components of the brake master cylinder and changing brake fluid every 2 years and replacing the brake hoses every 4. Doesn't mention anything about changing caliper seals..
that seems crazy calling a brake caliper a 'non serviceable item'! especially on a bike designed for hard charging overland adventures..
I can't see too many people standing for having to replace a complete caliper at 209 quid, thats 600 odd quid for the complete set !!
Guess its a case of 'watch this space'.

Hey KazakDan,

There will be 4 '08 Teneres passing through Almaty at the end of July, if you need anything specific for your Tenere (that I can carry), drop me a PM.

Russ

KazakDan!


In my opinion the front caliper is a servicable item for sure.

The Tenere front caliper looks like a standard Brembo caliper, so the piston sealings must be available. Maybe you should have a look to other off-road dealers which also can contact their country specific Brembo importer.

Caliper seals
 

I did ask if the dealer could tell which Brembo caliper it was but since Yamaha agreed to do it on warranty the investigation into seals stopped.

No Yamaha dealers here in Almaty (bike is still in UK anyway). If anyone finds this out or knows already, please let me know- I'll be taking a few seal kits with me on the overland journey for sure.

Thanks

I believe the calipers are the same as fitted to a KTM 640A (and possibly other bikes in the KTM range, as they all use Brembo brakes).

I think the problem you'll/have found is that UK dealers and/or Brembo are reluctant to offer 'service kits' for their calipers as they are (quite rightly) a fundamental safety item regarding the bike, and they don't want ham-fisted amateurs messing around with them and potentially killing themselves if their brakes subsequently fail? (I'm a member of a Ducati forum, and they seem to get the same situation regarding Brembo servicing...)

It's possible that a 'brake specialist' might be able to get the required parts, but as you have found out, with a bike that is at the most just a year old, it really is a warranty issue anyway I would have thought?

xxx

Ive had the same issue.

I was riding to work today when the rear break felt odd. It went on then suddenly dipped and didnt appear to work. I pulled over ASAP and it appears that one of the break pads has lifted off and torn off.

Last october during the MOT there was evidence of the breaking surface lifting off and the breaks were stripped and rebuilt with new pads.

It seems that they are a little too tight. Attempting to order in a new caliper has resulted in the same issue. Yamaha only sell the brembo break as the whole unit and not as parts... thus my only option is to either spend �360 (quoted) on a whole new unit (which at this time is well over 10% the value of the whole bike) or have them take it all apart and reassemble it all so it can happen again in 6 months.

(ive had the bike since 05 and Ive done 11k miles)

what with the front fork wheel clamp breaking/shearing off during a tyre change last year as well (at a shop to the recomended torque) Im getting a bit miffed with it all.

Sorry to hear of your trouble Kneebone - but I'd say that is just a pad issue?

Unless the caliper mounting pins are twisted (unlikely) the pads shouldn't be binding like that... Or if the piston is not retracting properly, then you ought to be able to get a new caliper under warranty?

As for the axle clamp breaking... well, the shop said they torqued them to the correct spec... but I bet they weren't - they only need to be nipped up and It's my guess someone was ham-fisted with it... those parts don't usually break on any bike...

xxx

Shocked at the calipers being a 'non servicable item' ! Yamaha calipers have traditionally needed servicing between every set of traffic lights .... I thought they'd gone for Brembo items to perhaps improve on this.

Ho ho - good gag good gag x

xxx

I can not see why you could not fined other seals beside OEM, I have never seen a brake system that could not be opened & seals found from them.

One would need to strip the brakes then do a little home work in looking for the seals. Most brake specialists could do the repair for you.

+1

Nissin, JAP and other brands sell repair kits, but Brembo doesn't, if you can not find the parts at your local seal shop, you could order then from http://www.tawvehicle.com/ at the states, there I was able to find brembro pistons.

have fun,

j.

08 Tenere seized front calipers - CONTD
 

Well, today I went to the bike after another 2 months storage and the second caliper is totally seized.

I will be riding to the shop tomorrow with one back brake... to get it fixed. They already agreed to do the right side under warranty and I am hoping they will do the left too.

What a crazy system- providing an unservicaeable caliper on a bike which will see more dirt and sand action than most other road going trailies. I am covered by warranty...

You could say that I have not taken good enough care of the bike (4 months storage should not require a brake overhaul/replacement surely?) but even so, if I can't service a normal, serviceable item like a piston seal on a caliper then what is the point in owning tools?

�209 per caliper for the front - before labour and fluids, is not an acceptable running cost.

Yamaha need to seriously rethink what they use and why they use it. Brembo normally equals quality and performance - but if the things seize after very mild neglect (storage after cleaning) then Yamaha need to replace under warranty with a better, serviceable item.

I am selling the bike owing to change in personal circumstances. But I would not be keen to keep it beyond the warranty period given this kind of experience.

Brembo
 

Also, why should I have to trawl the net to find some obscure supplier in the USA just to sort a common, everyday service issue.
It's not good enough. When you start measuring piston and comparing seals from KTM kits on the desk of the workshop, you know you are shaping up for a botch job.

Distinctly bad taste left in mouth... not happy.

We are only offering a alternate repair to replacing the parts if the bike was not under warranty, or stuck & have no other choice then to by new Yamaha parts.

I also agree with you I would not be happy & that it should not have seized up, I would like to know the reason why it seized, any chance you could ask the dealer to give you feed back as to why it seized. I would strongly suggest the dealer reports their finds to Yamaha so they can make sure this does not happen to other XTZ's

Any good mechanic would could easily measure up seals & guaranty that they will work.

KazakDan, hello, this is CaptMoto writing... I am the guvnor round here, nice to meet you.

Now... I presume from what I have read in these threads that your issue is a very isolated and unique one, in that no other Tenere owner has experienced this particular fault and it is unfortunate that you are having to go through this.

Most common problems that affected others, have been more or less all honoured by Yamaha under their repair warranty scheme.

I believe as a result that if the problem of your caliper seizing is rare, that you have a good cause for putting forward a warranty claim on the whole caliper set and demand a replacement on the basis that this is a very serious potential accident causing problem. God forbid you are cruising at 70 odd mph, and you apply the front brake only to find out the brake clamps your disk and doesn't let go. I see trouble.

What Kev has suggested, being a highly skilled mechanic is something that every good mechanic should be able to carry out and fix. However the point here is that you should not recur to this, you should expect Yamaha to fix it for you, free of charge and with a new safety tested caliper assembly to ensure that in a couple of months time you are not suing them for damages if your bike causes you to come off because the break has seixed.

I hope you appreciate all the suggestions that Kev and other are giving you in here, which is why we have this forum of discussion, i.e. to share our experience, lend a hand with the knowledge of those like Kev who have bags of it and I hope you were not being impertinent to those who helped you as that would be classed as ungrateful.

At the end of the day we can give you advices and suggestion but its Yamaha that has to pull their finger out and sort out your bike.

I myself am always grateful when I get free friendly advice.

Let us know how you get on and good luck

Seized calipers - false alarm?
 

Well, after the dealer inspected the piston not returning, he agreed to fit one front caliper on warranty. I on the day I was to ride it, the other caliper appeared to be jammed on.

Long story short, after a recovery to the shop it turned out that the issue was caused by the brake lever not returning fully because of the Barkbuster hand guards fouling the lever.

It was a question of millimetres but apparently enough to cause the problem. Hand guard removed, no issue. (but I got a free new caliper because they had already got it in).

Oh well...

Hee hee - priceless!

xxx

Having front caliper issues on my 2011 XTZ
 

Hi guys, I'm currently having front brake binding issues on my 2011 XTZ, my local dealer has suggested that I will need a pair of new calipers! On a bike that's been extremely well looked after and isn't even 3 years old yet!
Looking at this thread and how old it is I wondered if anyone has had any luck in finding a rebuild kit for these calipers or indeed found a suitable replacement?

Take a look at this thread:

http://www.xt660.com/showthread.php?...hlight=caliper

There are some posts from Pleiades which may help.

Good luck!

Sandman.

The above post (and link) is regarding the rear caliper on all XT models. All XTs share the same rear caliper (piston seals, sliders, boots etc.) with the BMW F650/700/800GS twins also the F/G650GS singles (although the BMs have a different mounting bracket).

For the front you need to reference the old F650GS and current G650GS singles to be sure you get the right parts. Although they only have one caliper, it is identical to that on the XTZ (and the XTR), but obviously you'll need two of everything.

The part numbers for the front repair kit for F800GS and G650GS appear to be the same, but I know the bigger GS twins take different pads, so the front caliper(s) quite possibly may not be exactly identical to the XTZ/R - they might fit, but I cannot guarantee it. However, I do know that the front repair kit for the F/G650GS single definitely does fit the XTZ and XTR caliper.

Here are the links to the parts needed:

Front caliper repair kit BRA51956 - http://www.motorworks.co.uk/vlive/Shop/Parts.php?T=5&NU=15&M=80&Ct=HA&SbCt=BA_15_80_HA_40


Rear caliper repair kit BRA51957 - http://www.motorworks.co.uk/vlive/Shop/Parts.php?T=5&NU=15&M=72&Ct=HA&SbCt=BA_15_72_HA_40

Thanks so much, sounds like I might actually be able to get a satisfactory repair done after all. Much appreciated!!

Now there is on Ebay also whole repair kit on sale with quite reaonable Price.
http://m.ebay.com/itm/151672578485?_mwBanner=1

These popped up as a listing last month. Finally somebody has sussed out there is a market for such a kit!

FYI - They also do a kit for the rear too:

http://www.ebay.com/itm/Yamaha-XT-66...item2351d8de90

The calipers are very similar to that of the f800gs calipers

So pistons and seal kits can be used from that model

I paid 32 GBP for a pair of caliper pistons

Hope this helps