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**antz.bin** · 07-16-2012, 12:23 PM

Query Approved

**aargee** · 07-16-2012, 12:28 PM

Had experienced exactly the same issue with CBR 250R; the culprit was the pads not being fixed properly at the caliper kit. If you're a DIY person, check that, or take it to ASC & ask them to check the position of the pads right in front of you. The position of the pads HAS to be perfectly parallel to each other.

**psr** · 07-16-2012, 12:52 PM

Originally posted by raj157 View Post

Hello friends, I am Ranjan. And i have a FAZER 153. I had bought my FAZER on September 2011. For the past few months(6) i have been facing a problem. The front disc brakes of my bike are not working properly

. I have attached some pictures of the problem. The thing is that. In general condition slight press on the brakes (front disc) works i.e maximum 1cm depression of the brakes

. But in my case it happens that sometimes i have to press very less(.5-1cm)for the discs to engage and sometimes i have to press completely but still the discs won't engage

. I feel very insecure while riding on the highway

, because i dont know what will happen when i press the front discs. I have complained regarding this to the service centre but they say this is normal. moreover when they try to check by pressing the lever,nothing happens. I have changed the oil of the discs,and have cleaned the pads from a very good mechanic at my place but still the problem persists. Its a threat to my safety but the yamaha guys won't listen as nothing happens infront of them. Please help guys. I am really worried

From what you have indicated the problem seems to be with master cylinder "O" ring failure....in the master cylinder there are two sealing rubber rings...if the one in front of piston fails then the problem you said will occur...since it is able to recover suggest the master cylinder be opened ,cleaned esp., the piston area,and refitted....debris in the master cylinder leads to the seals not holding compression of braking and leaking back into master cylinder leading to the occassional brake failure.
So open the master cylinder,clean the entire cylinder, and refit with preferably new "O" rings,and new oil..

**pavanchirmade** · 07-16-2012, 03:54 PM

+1 to psr. A friend's FZ had similar problem. The piston inside the brake master cylinder was replaced.

**raj157** · 07-16-2012, 04:36 PM

Originally posted by aargee View Post

Had experienced exactly the same issue with CBR 250R; the culprit was the pads not being fixed properly at the caliper kit. If you're a DIY person, check that, or take it to ASC & ask them to check the position of the pads right in front of you. The position of the pads HAS to be perfectly parallel to each other.

Bro i had checked the positon of the pads.. Its perfect...

**raj157** · 07-16-2012, 04:37 PM

Originally posted by psr View Post

From what you have indicated the problem seems to be with master cylinder "O" ring failure....in the master cylinder there are two sealing rubber rings...if the one in front of piston fails then the problem you said will occur...since it is able to recover suggest the master cylinder be opened ,cleaned esp., the piston area,and refitted....debris in the master cylinder leads to the seals not holding compression of braking and leaking back into master cylinder leading to the occassional brake failure.
So open the master cylinder,clean the entire cylinder, and refit with preferably new "O" rings,and new oil..

so what should i go and ask the service person to do....i am asking this because infront of the service person nothing happens.. They have tested and found nothing.. this happens only sometimes ...and most of the times when i am riding...

**raj157** · 07-16-2012, 04:39 PM

Originally posted by pavanchirmade View Post

+1 to psr. A friend's FZ had similar problem. The piston inside the brake master cylinder was replaced.

Bro is your friend here in this forum? can you plz contact him and ask what to do?

**somen1984** · 07-16-2012, 04:48 PM

Originally posted by raj157 View Post

Hello friends, I am Ranjan. And i have a FAZER 153. I had bought my FAZER on September 2011. For the past few months(6) i have been facing a problem. The front disc brakes of my bike are not working properly

. I have attached some pictures of the problem. The thing is that. In general condition slight press on the brakes (front disc) works i.e maximum 1cm depression of the brakes . But in my case it happens that sometimes i have to press very less(.5-1cm)for the discs to engage and sometimes i have to press completely but still the discs won't engage

. I feel very insecure while riding on the highway

, because i dont know what will happen when i press the front discs. I have complained regarding this to the service centre but they say this is normal. moreover when they try to check by pressing the lever,nothing happens. I have changed the oil of the discs,and have cleaned the pads from a very good mechanic at my place but still the problem persists. Its a threat to my safety but the yamaha guys won't listen as nothing happens infront of them. Please help guys. I am really worried

Actually it's air in your set up!! that means oil+air in the pipe or tank up! Even there can be a air leakage too.

Similarly had happen to my Aspire Front brake set up! it will some time work normally but some times it will press completely! when you try to press it very slowly or clamly then it will press completely!!

Get the set up check with the ASC!!

this is what my SVC guy had founf it, then he replaced my upper tank cover with nuts screws too. and never happened

**raj157** · 07-16-2012, 05:02 PM

Originally posted by somen1984 View Post

Actually it's air in your set up!! that means oil+air in the pipe or tank up! Even there can be a air leakage too.

Similarly had happen to my Aspire Front brake set up! it will some time work normally but some times it will press completely! when you try to press it very slowly or clamly then it will press completely!!

Get the set up check with the ASC!!

this is what my SVC guy had founf it, then he replaced my upper tank cover with nuts screws too. and never happened

Bro i had checked the whole system thrice. 2 times at yamaha (in different service center) 1nce at my place(known mechanic). So one thing is clear...they said no air in system.. They changed the oil ..thats it...and said that its normal...now what should i do ...and what should i tell the SC guys..

**psr** · 07-16-2012, 05:13 PM

Originally posted by raj157 View Post

so what should i go and ask the service person to do....i am asking this because infront of the service person nothing happens.. They have tested and found nothing.. this happens only sometimes ...and most of the times when i am riding...

If your bike is in warranty ask them to change the Master cylinder unit completely...if not ask them to service the master cylinder,and replace the master cylinder piston "O" rings...esp., to clean the inside of the master cylinder.

**Gyroerror** · 07-16-2012, 07:06 PM

Originally posted by raj157 View Post

Bro i had checked the whole system thrice. 2 times at yamaha (in different service center) 1nce at my place(known mechanic). So one thing is clear...they said no air in system.. They changed the oil ..thats it...and said that its normal...now what should i do ...and what should i tell the SC guys..

If you don't have any visible leaks around the caliper dust seals then its most likely to be the master cylinder o-ring as psr mentioned. A master cylinder is relatively cheap so I would go for a replacement but if you are tight for cash a new piston/0-ring/spring kit would suffice.

Check if you are losing fluid by keeping a tab on the oil level, if the level is dropping check the dust seals around the caliper pistons (best way to do this would be to let them collect dust and then observe if you have any damp patches). If all is ok then its your master cylinder at fault.

**raj157** · 07-16-2012, 10:00 PM

Originally posted by Gyroerror View Post

If you don't have any visible leaks around the caliper dust seals then its most likely to be the master cylinder o-ring as psr mentioned. A master cylinder is relatively cheap so I would go for a replacement but if you are tight for cash a new piston/0-ring/spring kit would suffice.

Check if you are losing fluid by keeping a tab on the oil level, if the level is dropping check the dust seals around the caliper pistons (best way to do this would be to let them collect dust and then observe if you have any damp patches). If all is ok then its your master cylinder at fault.

There is no leakage or damp parts brother. and my bike is still under warranty . its 8 months old.

**raj157** · 07-16-2012, 10:02 PM

Originally posted by psr View Post

If your bike is in warranty ask them to change the Master cylinder unit completely...if not ask them to service the master cylinder,and replace the master cylinder piston "O" rings...esp., to clean the inside of the master cylinder.

Will changing the master cylinder unit completely solve the problem. Moreover the Servicecenter ppl say that there is no problem. SO will they replace it under warranty if i say to do that..

**psr** · 07-16-2012, 10:09 PM

Originally posted by raj157 View Post

Will changing the master cylinder unit completely solve the problem. Moreover the Servicecenter ppl say that there is no problem. SO will they replace it under warranty if i say to do that..

Show them the photos of the fully pressed brake lever and insist on replacement...if they refuse still, then write down on the job card , or take a letter addressed to them detailing the problem and attaching the photo as proof...and make it clear that if there is an accident you will sue them for supplying below par DEFECTIVE vehicle,and claim compensation from them .Mark the letter to Yamaha regional office also.

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Front Disc problem With MY FAZER

Front Disc problem With MY FAZER

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