REAR BRAKE

8-76 CHASSIS

*This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based.

*Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

*When storing the brake fluid, seal the container completely and keep away from children.

*When replenishing brake fluid, take care not to get dust into fluid.

*When washing brake components, use fresh brake fluid. Never use cleaning solvent.

*A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent.

Handle brake fluid with care: The fluid reacts chemically with paint, plastics, rubber materials etc. and will damage then severely.

BRAKE PAD REPLACEMENT

*Do not operate the brake pedal with the pads removed.

*Replace the brake pads as a set, otherwise braking performance will be adversely affected.

•Install the new brake pads.

Pad mounting pin: 15 N·m (1.5 kgf-m, 11.0 lb-ft)

Brake caliper mounting bolt: 17 N·m (1.7 kgf-m, 12.5 lb-ft)

NOTE:

After replacing the brake pads, pump the brake pedal a few times to set the brake parts correctly and then check the brake fluid level.

CHASSIS 8-77

BRAKE FLUID REPLACEMENT

• Remove the brake fluid reservoir mounting bolt 1.

• Place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap 2.

•Replace the brake fluid in the same manner as the front brake. ( 8-66)

Specification and classification: DOT 4

Bleed air from the brake system. ( 2-23)

NOTE:

Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid.

•Remove the pad mounting pin 2.

•Remove the caliper mounting bolt 3.

•Remove the brake caliper.

Never reuse the brake fluid left over from previous servicing and stored for long periods.

Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage.

8-78 CHASSIS

•Remove the brake pad spring.

•Remove the caliper air bleeder valve 4.

•Remove the spacer 5 and rubber boot 6 from the caliper.

CHASSIS 8-79

CALIPER INSPECTION

BRAKE CALIPER AND BRAKE CALIPER PISTON

•Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one.

•Inspect the brake caliper piston surface for any scratches and other damage. If any damage is found, replace the caliper with a new one.

BRAKE PAD SPRING BOOTS AND SPACER

•Inspect the brake pad spring for damage and excessive bend. If any damage is found, replace the brake pad spring with a new one.

•Inspect the boots and spacer for damage and wear. If any damage is found, replace boot and spacer with new ones.

E

L

P

M

A

S

BRAKE DISC INSPECTION

•Inspect the rear brake disc in the same manner as the front brake disc. ( 8-70)

Service Limit

Rear disc thickness: 4.5 mm (0.18 in) Rear disc runout: 0.30 mm (0.012 in)

CHASSIS 8-81

CALIPER INSTALLATION

Install the caliper in the reverse order of removal. Pay attention to the following points:

• Tighten each bolt to the specified torque.

Brake hose union bolt 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Brake caliper mounting bolt 2:

17 N·m (1.7 kgf-m, 12.5 lb-ft) Brake caliper pin bolt 3: 32 N·m (3.2 kgf-m, 23.0 lb-ft)

2-20)

MASTER CYLINDER REMOVAL AND

DISASSEMBLY

• Loosen the lock-nut 4.

• Remove the mounting bolts 5.

Immediately and completely wipe off any brake fluid contacting any parts of the motorcycle. The fluid reacts chemically with paint, plastic and rubber materials, etc. and will damage them severely.

•Disconnect the reservoir hose.

•Remove the master cylinder by turning the master cylinder rod 6.

8-82 CHASSIS

•Remove the reservoir cap 7, insulator 8, diaphragm 9 and reservoir tank 0.

• Remove the snap ring A with the special tool.

09900-06108: Snap ring pliers

• Pull out the dust boot D, then remove the snap ring E.

09900-06108: Snap ring pliers

• Remove the following parts.

F Push rod

G Secondary cup H Piston

I Primary cup J Return spring

CHASSIS 8-83

MASTER CYLINDER INSPECTION

CYLINDER, PISTON AND CUP SET

•Inspect the cylinder bore wall for any scratches or other damage.

• Inspect the cup set and each rubber part for damage.

MASTER CYLINDER REASSEMBLY

Reassemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

8-84 CHASSIS

MASTER CYLINDER INSTALLATION

Install the master cylinder in the reverse order of removal. Pay attention to the following points:

• Apply THREAD LOCK to the master cylinder mounting bolts.

99000-32110: THREAD LOCK SUPER “1322”

(or equivalent thread lock)

• Tighten each bolt to the specified torque. (Brake hose routing: 10-25)

Brake hose union bolt 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Master cylinder mounting bolt 2:

10 N·m (1.0 kgf-m, 7.0 lb-ft) Master cylinder rod lock-nut 3:

18 N·m (1.8 kgf-m, 13.0 lb-ft)