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.

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

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"Where we're going, we don't need roads..."

JennyDakar.com

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.

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2011 XT660Z, in BLACK of course!
Mods done:
Lost the will to keep track!

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

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