13. Brake System Service Information Troubleshootit 9 Brake Pad Replacement Front Master Cylinder Disassembly/ Assembly Front Brake Caliper Disassembly/ Assembly 13-1 Rear Master Cylinder Disassembly/ 43.1 Assembly 13-8 14.2 Rear Brake Caliper Disassembly! -2 assembly 13-10 19.4 Rear Brake Pedal Removal/Installation 13-12 13-6 Service information xm + A contaminated brake dise or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent + In 1d asbestos fibers have been found to cause respiratory disease and cancer. Never use an ait hose o1 dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard of airborne asbestos fibers. + Spilled brake fluid will severely damage 'strument lenses and painted surfaces. It is also harmful to some rubber parts. Be very careful whenever you remove the reservoir cap: make sure the front reservoir is horizontal first. + Never allow contaminants (dirt, water, etc.) to get into an open reservoir + Once the hydraulic system has been opened, or if the biakes feel spongy, the system must be bled. + Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid i as they may not be compatible. + Always check brake operation before riding the motoreycle. Troubleshooting Brake Lever/Pedal Soft or Spongy + Air bubbles in the hydraulic system + Leaking hydraulic system + Contaminated brake padidise + Worn caliper piston seal + Worn master cylinder piston cups Worn brake padidise Contaminated caliper Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston Sticking/worn master cylinder piston Contaminated master cylinder + Bent brake lever/pedal Brake Lever/Pedal Hard + Cloggedirestricted brake system Sticking/worn caliper piston + Caliper not sliding properly + Cloggedirestricted fluid passage + Worn caliper piston seal + Sticking/worn master cylinder piston + Bont brake lever/pedal Brake Drag + Conteminated brake padidise + Misaligned wheel + Baaly worn Drake padidise + Warpedideformed brake disc + Caliper not sliding properly + Cloggedirestricted fluid passage + Sticking/orn caliper piston 13-1"Brake System Brake Pad Replacement Front Pad spring 13-20 Brake System + Accontaminated brake disc oF pad reduces stopping power, Discard contaminated pads and clean @ contaminated dise with a high quality brake degreasing agent + Inhaled asbestos fibers have been found 10 cause respiratory disease and cancer. + After replacement, operate the brake lever to seat the caliper pistons against the pads. Never use an air hose or dry brush to clean brake assemblies, Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize she hazard of airborne asbestos fibers Note + The brake pads can be replaced without disconnecting the hydraulic system. Replace the brake pads as a set, Apply a thin coat of grease onto the pad pin and pad pin plug threads to prevent rust oy Remarks Removal Order Installation is in the reverse order of removal (1) | Pad pin plug 1 (2) | Pad pin 1 (3) | Pad 2 NOTE | + Push the pistons all the way in to provide clearance the | new pods. + Before installing the pads, make sure that the pad spring is positioned properly as showa. 13-3Brake System Front Master Cylinder Disassembly/Assembly 13) Suey \\ KO (9) | ~ a SEX ea | dl | dire Pgh o \ ge Gar Tay 6 (0.6, 4.3) (3) Bevvo. 40 13-4Brake System + Check the brake system by applying the brake after bleeding CAUTION Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system Is serviced When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to enter the system. | + Do not allow the lips of the cups to turn inside out and be eettain the snap ring is firmly seated in the groove, NOTE + Use only DOT 4 brake fluid from a sealed container. Requisite Service + Front brake fluid deaining/bleeding (section 17 in Common Service Manual) Procedure ow | Remarks Disassembly Oeder | [Assembly is in the reverse order of disessembly. (2) | Rear view mirror 1 (2) | Brake switen wir 2 | 3) | Brake lever pivot nut/collar wm | Kouckle guard (4) | Brake lever pivot bolt 1 | (6) Brake lever om Or boi 1 1 (8) | Sealing washer z (9) | Brake hose 4 (10)] Master einer holder bot 2 111 Master cylinder holder 1 | Remove the master cylinder assembly from the handlebar (12)] Brake switch 1 113)| Reservoir cop screw 2 | (14) Reservoin eae 1 5}, Set plate/aiaphragr y (161) Boot + (1711 Snap ring 1 (18), Raster piston i (19)| Spring a4 Use snap ring piers (07914 ~ 3230001) 13-5Brake System Front Brake Caliper Disassembly/Assembly 1 oO} - Qs08107 oy ae Bovuss SG re g / 3003.22) Qeevess 13-6Brake System om ~ contaminated brake dic o pd reduces stoping power. Discard contaminated pads and clean contaminated die OS movers Ses hose ov ry oun to leon brake ascombtes, Use on OSHA approved vacuum clearer or aerate Inethod approved bv OSHA, designed to mi dof albare asbeston fiers CAUTION ) + Spilled brake fluid NOTE damage painted, plastic, or rubber parts. After replacement, operate the brake lever to seat the caliper pistons againt the pads. + Do not remove the bleed valve unless it is replaced, @ Requisite Service + Front brake fluid draining/bleeding (section 17 in Common Service Manual) Procedure oy | Remarks Disassembly Order | Assembly is in the reverse order of disassembly Oi at 1 Sealing washer 2 13) | Brake hose 1 (3) | Poa 2 | Removalinstalation ipage 13:2) (5) | Catipar mounting bole 2 (8) | Brake caliper assembiy 1 (7) | Pad spring 1 | instal 25 shown (9) | Caliper Dacker 1 Jia eecretainer 1 (101) Caliper pin bolt boot 2 (111) Caliper pin bolt 2 | Donat remove unless necess (12)| Caper piston 2 (13)| Dust seal 2+caution (14 Piston seal 2 | -'b0 careful not to damage the plston sliding surface. 13-7Brake System Rear Master Cylinder Disassembly/Assembly 13-8Brake System + Check the brake system by applying the brake aft bleeding. CAUTION Avoid spilling fluid on painted, plastic, or rubber parts, Place a rag over these parts whenever the system is serviced, When removing the oil bolt. cover the end of the brake hose to prevent contamination, Do not allow foreign material 10 enter the system. + Do not allow the lips of the cups to turn inside out and be certain the snap ring is firmly seated in the groove. NOTE Use only DOT 4 brake fluid from a sealed container, The master piston, piston cups and spring must be replaced as a set, Requisite Service Rear brake fluid draining/bleeding (section 17 in Common Service Manvel! Procedure Low | Remarks Disassembly Order ‘Assembly is in the reverse order of disassembly. (1) | obo 1 (2) | Sealing washer (3) | Brake hose 1 | Atinstallation, align the brake hose fitting with the master cylinder grooves. (4) | Cotter pin (5) | Joint pin 1 1 16) | Mounting bolt 2 | (7) | Snap ring + | Use snap rng pliers (07914~3230001) 18) | Reservot hose joint | : (9) | Oving i (10)| Master cylinder assembly 1 113] Leck nut + | Loosen the mut 112)| Push rod joint 1 (13), Boot 1 (18), Snap ring | 1. | Use snap ring pliers 107914~3230001) (98), Push rod 14 (16), Master piston | 4 (17), Spring 1 13-9Brake System Rear Brake Caliper Disassembly/Assembly 13-10Brake System A contaminated brake dise ot oad reduces stopping power, Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Chock the brake system by applying the brake after the air bleeding + Inhaled asbestos fibers have been found to cause respiratory disease and cancer + Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard of aitborne asbestos fibers. CAUTION brake fluid will damage painted, plastic, or eubber parts. unless itis replaced. Do not remove the ble 4 Requisite Service + Rear brake fluid draining/bleeding (sectian 17 in Common Service Manual) + Rear wheel removalfinstallation (page 12-2) Procedure ay Remarks | Disassembly Order Assembly is in the reverse order of disassembly. cy | Pag 2 _ | Removalfirtallation (page 13-2) (2) | Caliper stopper pin bott 1 (3) | oi bot 1 | Remove the brake hose from the clamp and swing the caliper rearward, (| Seating washer 2 ya neiee : (8 Gainer brtckor i (1) extber pin ett ; {12} eetber ston ' Do not remove unless necessary. —p caution + Be careful not to damage the piston sliding surface. 13-11Brake System Rear Brake Pedal Removal/Installation “5 2 ge Procedure Remarks Removal Order (1) | Brake tight switch spring (2) | Cotter pin (3) Joint pin (4) | Brake pedal return spring (5) | Cotter pin/washer (6) | Brake pedal Installation is in the 1everse order of removal. 13-12