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