BRAKES 12-1
Brakes
Table of Contents
Exploded View................................... |
12-2 |
Specifications .................................... |
12-6 |
Special Tool ....................................... |
12-7 |
Brake Lever, Brake Pedal.................. |
12-8 |
Brake Lever Position Adjustment. |
12-8 |
Brake Pedal Position Inspection .. |
12-8 |
Brake Pedal Position Adjustment. |
12-8 |
Calipers ............................................. |
12-9 |
Front Caliper Removal ................. |
12-9 |
Rear Caliper Removal.................. |
12-9 |
Caliper Installation ....................... |
12-9 |
Front Caliper Disassembly........... |
12-10 |
Front Caliper Assembly................ |
12-10 |
Rear Caliper Disassembly ........... |
12-11 |
Rear Caliper Assembly ................ |
12-12 |
Caliper Fluid Seal Damage .......... |
12-12 |
Caliper Dust Seal/Friction Boot |
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Damage..................................... |
12-12 |
Caliper Piston and Cylinder |
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Damage..................................... |
12-13 |
Caliper Holder Shaft Wear ........... |
12-13 |
Brake Pads........................................ |
12-14 |
Front Brake Pad Removal............ |
12-14 |
Front Brake Pad Installation......... |
12-14 |
Rear Brake Pad Removal ............ |
12-14 |
Rear Brake Pad Installation ......... |
12-14 |
Brake Pad Wear Inspection ......... |
12-14 |
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Master Cylinder ................................. |
12-15 |
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Front Master Cylinder Removal ... |
12-15 |
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Front Master Cylinder Installation |
12-15 |
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Rear Master Cylinder Removal.... |
12-16 |
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Rear Master Cylinder Installation. |
12-16 |
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Front Master Cylinder |
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Disassembly.............................. |
12-16 |
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Rear Master Cylinder |
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Disassembly.............................. |
12-17 |
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Master Cylinder Assembly ........... |
12-17 |
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Master Cylinder Inspection (Visual |
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Inspection)................................. |
12-17 |
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Brake Disc ......................................... |
12-18 |
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Brake Disc Removal .................... |
12-18 |
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Brake Disc Installation ................. |
12-18 |
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Brake Disc Wear .......................... |
12-18 |
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Brake Disc Warp .......................... |
12-18 |
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Brake Fluid ........................................ |
12-19 |
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12 |
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Brake Fluid Level Inspection........ |
12-19 |
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Brake Fluid Change ..................... |
12-19 |
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Brake Line Bleeding..................... |
12-19 |
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Brake Hose........................................ |
12-20 |
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Brake Hose Removal/Installation. |
12-20 |
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Brake Hose Inspection................. |
12-20 |
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12-2 BRAKES
Exploded View
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BRAKES 12-3 |
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Exploded View |
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No. |
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Front caliper mounting bolts |
34 |
3.5 |
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25 |
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2 |
Brake hose banjo bolts |
25 |
2.5 |
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18 |
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3 |
Bleed valve |
7.8 |
0.80 |
69 in·lb |
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4 |
Brake lever pivot bolt |
1.0 |
0.10 |
9 |
in·lb |
Si |
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5 |
Brake lever pivot bolt locknut |
5.9 |
0.60 |
52 in·lb |
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6 |
Front brake disc mounting bolts |
27 |
2.8 |
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20 |
L |
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7 |
Front brake light switch screws |
1.0 |
0.10 |
9 |
in·lb |
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8 |
Front brake reservoir cap screws |
1.0 |
0.10 |
9 |
in·lb |
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9 |
Front master cylinder clamp bolts |
8.8 |
0.90 |
78 in·lb |
S |
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B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specific tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
12-4 BRAKES
Exploded View
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BRAKES 12-5 |
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Exploded View |
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No. |
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Rear master cylinder push rod locknut |
18 |
1.8 |
13 |
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2 |
Rear caliper mounting bolts |
25 |
2.5 |
18 |
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3 |
Brake hose banjo bolts |
25 |
2.5 |
18 |
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4 |
Bleed valve |
7.8 |
0.80 |
69 in·lb |
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5 |
Rear master cylinder mounting bolts |
25 |
2.5 |
18 |
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6 |
Rear brake disc mounting bolts |
27 |
2.8 |
20 |
L |
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B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).
12-6 BRAKES
Specifications
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Item |
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Standard |
Service Limit |
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Brake Lever, Brake Pedal: |
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Brake lever position |
5-way adjustable (to suit rider) |
– – – |
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Brake lever free play |
Non-adjustable |
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– – – |
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Pedal free play |
Non-adjustable |
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– – – |
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Pedal position |
About 47 mm (1.85 in.) below footpeg top |
– – – |
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Brake Fluid: |
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Grade |
DOT4 |
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– – – |
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Brake Pads: |
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Lining thickness: |
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Front |
4.5 mm (0.18 in.) |
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1 mm (0.04 in.) |
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Rear |
5 mm (0.20 in.) |
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1 mm (0.04 in.) |
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Brake Discs: |
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Thickness: |
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Front |
4.3 |
4.5 mm (0.17 |
0.18 in.) |
4.0 mm (0.16 in.) |
Rear |
4.8 |
5.2 mm (0.19 |
0.20 in.) |
4.5 mm (0.18 in.) |
Runout |
Not more than 0.2 mm (0.008 in.) |
0.3 mm (0.012 in.) |
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