12-8 BRAKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever adjuster has 5 positions so that the brake lever• position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
○The distance from the grip to the lever is minimum at number 5 and maximum at number 1.
Brake• Pedal Position Inspection
Check that the brake pedal [A] is in the correct position. Footpeg [B]
Pedal Position
Standard: About 47 mm (1.85 in.) [C] below top of footpeg
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
○Usually it is not necessary to adjust the pedal position, but always adjust it when the push rod locknut has been loosened.
•Remove the bolts [A] and remove the guard bracket [B].
•Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position.
If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), the
•pedal position will be within the standard range. Tighten:
Torque - Rear Master Cylinder Push Rod Locknut:
• 18 N·m (1.8 kgf·m, 13 ft·lb)
Check the brake light switch operation (see Brakes in the Periodic Maintenance chapter).
BRAKES 12-9
Calipers
Front• Caliper Removal
Loosen the banjo bolt [A] at the brake hose lower end,
•and tighten it loosely.
Unscrew the caliper mounting bolts [B], and detach the
•caliper [C] from the disc.
Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○After the caliper removal, if compressed air will not be available for disassembling the caliper, remove the piston before detaching the brake hose (see Front Caliper Disassembly).
Rear• Caliper Removal
Loosen the banjo bolt [A] at the brake hose lower end,
•and tighten it loosely.
Unscrew the caliper mounting bolts [B], and detach the
•caliper [C] from the disc.
Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○After the caliper removal, if compressed air will not be available for disassembling the caliper, remove the piston before detaching the brake hose (see Rear Caliper Disassembly).
Caliper• Installation
Install the caliper and brake hose lower end.
○Replace the washers on each side of hose fitting with new
•ones. Tighten:
Torque - Caliper Mounting Bolts (Front): 34 N·m (3.5 kgf·m, 25 ft·lb)
Caliper Mounting Bolts (Rear): 25 N·m (2.5 kgf·m, 18 ft·lb)
• Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
•Check the fluid level in the brake reservoirs.
•Bleed the brake line (see Bleeding the Brake Line). Check the brake for good braking power, no brake drag, and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first application of the lever or pedal if this is not done.
12-10 BRAKES
Calipers
Front• Caliper Disassembly
Remove:
Front Caliper (see Caliper Removal)
Brake Pads and Springs (see Brake Pad Removal)
•Using compressed air, remove the pistons. ○Cover the piston area with a clean, thick cloth [A].
○Blow compressed air [B] into the hole for the banjo bolt to remove the piston.
WARNING
To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
○•Pull out the pistons by hand.
•Remove the dust seals [A] and fluid seals [B]. Remove the bleed valve [C] and rubber cap [D].
Front• Caliper Assembly
Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
•Install the bleed valve and rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
BRAKES 12-11
Calipers
•Replace the fluid seals [A] with new ones.
○Apply brake fluid to the fluid seals, and install them into
•the cylinders by hand.
Replace the dust seals [B] with new ones if they are damaged.
○Apply brake fluid to the dust seals, and install them into the cylinders by hand.
•Apply brake fluid to the outside of the pistons, and push
•them into each cylinder by hand.
Check the shaft rubber friction boot [A] and the dust cover
•[B] replace them with new ones if they are damaged. Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease).
•Install the anti-rattle spring [A].
•Install the pads (see Front Brake Pad Installation).
•Wipecloth. up any spilled brake fluid on the caliper with wet
Rear• Caliper Disassembly
•Remove the rear caliper.
Remove the pads and anti-rattle spring (see Rear Brake
•Pad Removal).
Using compressed air, remove the piston. ○Cover the piston area with a clean, thick cloth [B].
○Blow compressed air [A] into the hole for the banjo bolt to remove the piston.
WARNING
To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
•Remove the dust seal and fluid seal.
•Remove the bleed valve and rubber cap.
12-12 BRAKES
Calipers
Rear• Caliper Assembly
Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
•Install the bleed valve and rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
•Replace the fluid seal [A] with a new one.
○Apply brake fluid to the fluid seal, and install it into the
•cylinder by hand.
Replace the dust seal [B] with a new one if it is damaged. ○Apply brake fluid to the dust seal, and install it into the
cylinder by hand.
•Apply brake fluid to the outside of the piston, and push it
•into the cylinder by hand.
Replace the shaft rubber friction boot [A] and dust cover
•[B] if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease).
•Install the anti-rattle spring [A] in the caliper as shown.
•Install the pads (see Rear Brake Pad Installation).
•Wipecloth. up any spilled brake fluid on the caliper with wet
Caliper• Fluid Seal Damage
Refer to the Brakes in the Periodic Maintenance chapter.
Caliper• Dust Seal/Friction Boot Damage
Refer to the Brakes in the Periodic Maintenance chapter.