Brakes

CAUTION: Disc brake components rarely require disassembly. Do not disassemble components unless absolutely necessary. If any hydraulic connection in the system is opened, the entire system should be disassembled, drained, cleaned and then properly filled and bled upon reassembly. Do not use solvents on brake internal components. Solvents will cause seals to swell and distort. Use only clean brake fluid for cleaning. Use care with brake fluid. Brake fluid is injurious to eyes and will damage painted surfaces and plastic parts.

Caliper pad replacement

It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.

1.      Remove the brake caliper securing bolts and remove the brake caliper assembly.

2.      Remove the brake caliper cover.

1. Brake caliper cover

3. Remove the pad retaining clips.

1. Pad retaining clip

4. Pull out the pad retaining pins and remove the pad spring.

1 Pad retaining pin 2. Pad spring

5. Remove the brake pads.

1. Brake pad

6. Install the new brake pads and shims. Before installing the pads, install the shim on the back plate which faces the caliper piston. Also replace the following parts if pad replacement is required.

NOTE: Replace the pads as a set if either is found to be worn to the wear limit.

a.    Pad retaining clips

b.    Pad retaining pins

c.    Pad spring

d.    Brake pads

e.    Shims

Caliper disassembly

1.      Remove the caliper brake hose. Allow fluid in the caliper assembly to drain into a container.

2.      Place the open hose end into the container and pump the old fluid out carefully.

3.      Remove the caliper support bolts and the brake pads as described in the caliper pad replacement procedure.

4.      Remove the caliper assembly from the caliper frame.

5.      Remove the retaining ring and the dust seal.

6.      Remove the piston.

CAUTION: Cover the piston with a rag. Use care so that the piston does not cause injury as it is expelled from the cylinder.

7. Remove the piston seal.

Master cylinder disassembly

1. Front master cylinder a. Remove the brake light switch.

b. Remove the brake hose.

c.    Remove the brake lever and spring.

d.    Remove the master cylinder from the handlebar. Remove the reservoir cap and drain the remaining fluid.

e.    Remove the master cylinder dust boot

f.    Remove the snap ring.

g.    Remove the master cylinder cup assembly. Note that the cylinder cups are installed with the larger diameter (lips) inserted first.

Brake inspection and repair

Recommended brake component

Replacement schedule: Brake pads; As required Piston seal, dust seal; Every two years Brake hoses; Every four years Brake fluid; Replace only when brakes are disassembled

1. Replace the caliper piston if it is scratched.

2. Replace any brake pad worn beyond limits. Always replace the brake pads as a set.

Wear limit:

Front and rear 0.5 mm (0.020 in)

See Caliper pad replacement procedure for a listing of the parts to be replaced when pads are replaced.

3.      Replace piston and dust seals if damaged. Replace seals every two years.

4.      Inspect master cylinder body. Replace if scratched. Clean all passages with new brake fluid.

5.      Inspect the brake hoses. Replace every four years or immediately if cracked, frayed, or damaged.

6.      Check for wear and deflection of disc.

Maximum deflection (front and rear):

0.15 mm (0.006 in) Minimum disc thickness:

Front: 7.0 mm (0.28 in)

Rear: 8.0 mm (0.32 in)

WARNING: If disc is worn beyond minimum thickness or deflection exceeds specified amount, replace disc.

MASTER CYLINDER

Brake reassembly

1.      All internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed.

2.      Caliper reassembly

Replace the following parts whenever a caliper is disassembled: bleed screw and cap, piston seal, dust seal, and retaining ring.

a.     Install the piston seal and piston. Place the caliper cylinder into the caliper frame.

b.    Install the shims, brake pads, pad spring, pad retaining pins and the pad retaining clips.

c.     Install the caliper assembly on the front fork (For front brake). Install the caliper assembly on the bracket (For rear brake).

NOTE:  Apply a thread locking compound such as "LOCTITE" to the support bolts.

Caliper support bolt torque: 35 Nm (3.5 mkg, 25 ft-lb)

3. Attach the brake hoses.

Brake hose torque: 26 Nm (2.6 mkg, 19 ft lb)

4. Master cylinder reassembly

Reassemble master cylinder as shown in illustration.

Brake hose torque: (all brake union blots) 26 Nm (2.6 mkg, 19 ft-lb)

5. Brake disc assembly

If the brake disc has been removed from the hub or is loose, tighten the bolts.

Disc bolt torque: 20 Nm (20 m-kg, 14 ft-lb)

6. Air bleeding

NOTE:  Bleed the brake system in order of the following steps.

1.      Anti-dive unit

2.      Front brake caliper

3.      Rear brake caliper

WARNING: If the brake system is disassembled or if any brake hose has been loosened or removed, the brake system must be bled to remove air from the brake fluid. If the brake fluid level is very low or brake operation is incorrect, bleed the brake system.

Failure to bleed the brake system properly can result in a dangerous loss of braking performance.

a.     Add proper brake fluid to the reservoir. Install the diaphragm, being careful not to spill or overflow the reservoir.

b.    Connect the clear plastic tube of 4.5 mm (3/16 in) inside diameter tightly to the bleed screw. Put the other end of the tube into a container.

c.     Slowly apply the brake lever or pedal several times. Pull in the lever (push down the pedal). Hold the lever or pedal in "on" position. Loosen the bleed screw. Allow the lever or pedal to travel slowly toward its limit When the limit is reached, tighten bleed screw. Then release the lever (or pedal).

d.    Repeat step "c" procedure until all air bubbles are removed from system.

NOTE:  If bleeding is difficult it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system settle out.

Brake disc installation

1. When installing the brake disc(s), the slots on the disc should be positioned as shown.

NOTE: Make sure the directions in which discs are installed. For this purpose an identification mark is stamped on the brake disc.

1. Slot 2. Identification mark (Rotating direction)

1. Slot 2 Identification mark (Rotating direction)