2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•If it does not, adjust and inspect the brake light switch. While holding the switch body, turn the adjusting nut [A] to adjust the switch.

CAUTION

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

•Remove the right side cover (see Frame chapter).

•Disconnect the connector [A].

•Using a hand tester, inspect to see that only the connection shown in the table have continuity (about zero ohms).

Special Tool - Hand Tester: 57001–1394

Rear Brake Light Switch Connections:

If the switch has an open or short, replace it with a new one.

Caliper Fluid Seal Damage

The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise• brake and brake fluid temperature.

•Remove the calipers (see Brakes chapter).

Replace the fluid seals under any of the following conditions; (a) fluid leakage around the pad; (b) brakes overheat (c) there is a large difference in inner and outer pad wear; (d) the seal is stuck to the piston.

If the fluid seal is replaced, replace the dust seals [B] as well. Also, replace all seals every other time the pads are changed.

Caliper• Dust Seal/Friction Boot Damage

•Remove the calipers (see Brakes chapter).

Check that the dust seals [B] and friction boots [C] are not

•cracked, worn, swollen, or otherwise damaged.

If they show any damage, remove the caliper bracket and replace them.

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures

Master• Cylinder Inspection (Visual Inspection)

•Remove the master cylinders (see Brakes chapter).

•Disassemble the front and rear master cylinders.

Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].

If a master cylinder or piston shows any damage, replace

•them.

Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups.

If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.

Front Master Cylinder [J]

•Check the dust covers [E] for damage.

•If they are damaged, replace them.

Check the piston return springs [F] for any damage.

•If the springs are damaged, replace them.

Check that relief port [G] and supply port [H] are not plugged.

If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

Rear Master Cylinder [K]

PERIODIC MAINTENANCE 2-33

Periodic Maintenance Procedures

•Level the brake fluid reservoir.

•Remove the reservoir cap and diaphragm.

•Remove the rubber cap from the bleed valve [A] on the

•caliper.

Attach a clear plastic hose [B] to the bleed valve, and run

•the other end of the hose into a container.

Fill the reservoir with fresh specified brake fluid.

•Change the brake fluid:

○Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].

2. Apply the brake and hold it [B].

3. Close the bleed valve [C].

4. Release the brake [D].

NOTE

○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line.

○Front Brake: Repeat the above steps for the other caliper.

○Rear Brake: Repeat the above steps for the other bleed valve.

•Remove the clear plastic hose.

•Install the reservoir cap.

•Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.0 N·m (0.10 kgf·m, 9 in·lb)

•Follow procedure below to rear brake fluid reservoir cap ○correctly.First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake

fluid reservoir body [A].

•Tighten the bleed valve, and install the rubber cap.

•Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.

If necessary, bleed the air from the lines.