Monthly Archives: Февраль 2014

HYDRAULIC BRAKE

COMPONENT LOCATION

HYDRAULIC BRAKE

SERVICE INFORMATION

GENERAL

A WARNING

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.

• Avoid breathing dust particles.

• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

NOTICE

Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.

• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with high quality brake degreasing agent.

• Check the brake system by applying the brake lever or pedal after the air bleeding.

• Never allow contaminates (dirt, water, etc.) to get into an open reservoir.

• Once the hydraulic system has been opened, or if the brake feels 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, they may not be compatible.

• Always check brake operation before riding the motorcycle.

SPECIFICATIONS

Unit: mm (in

ITEM

STANDARD

SERVICE LIMIT

Front

Brake fluid

DOT 4

Brake disc thickness

3.0 (0.12)

2.5(0.10)

Brake disc warpage

0.15 (0.006)

Master cylinder I. D.

11.000(0.4331)

11.050 (0.4350)

Master piston O. D.

10.971 (0.4319)

10.840 (0.4268)

Caliper cylinder I. D.

27.025 (1.0640)

27.060 (1.0654)

Caliper piston O. D.

26.968 (1.0617)

26.853 (1.0572)

Rear

Brake fluid

DOT 4

Brake disc thickness

4.0(0.16)

3.5(0.14)

Brake disc warpage

0.15 (0.006)

Master cylinder I. D.

9.547 (0.3759)

9.575 (0.3770)

Master piston O. D.

9.491 (0.3737)

9.465 (0.3726)

Caliper cylinder I. D.

22.650 (0.8917)

22.712 (0.8942)

Caliper piston O. D.

22.620 (0.8905)

22.573 (0.8887)

Brake pedal push rod standard length

79.6 mm (3.13 in)

TORQUE VALUES

Brake hose oil bolt

Brake lever pivot nut

Brake lever pivot bolt

Brake lever adjuster lock nut

Front master cylinder reservoir cover screw

Front master cylinder holder bolt

Front brake caliper mounting bolt

Front/rear caliper bleed valve

Rear master cylinder reservoir cover bolt

Rear master cylinder mounting bolt

Brake caliper pad pin

Front brake caliper pad pin plug

Brake pedal pivot bolt

Brake pedal adjuster lock nut

Front brake disc cover bolt

34 N m (3.5 kgf-m, 25 Ibf-ft)

5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft)

1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft)

5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft)

1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft)

Apply locking agent to the threads

9.9 N-m (1.0 kgf-m, 7.3 Ibf-ft) 30 N-m (3.1 kgf-m, 22 Ibf-ft) 5.4 N-m (0.6 kgf-m, 4.0 Ibf-ft)

1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft) 13 N-m (1.3 kgf-m, 10 Ibf-ft) 18 N-m (1.8 kgf-m, 13 Ibf-ft)

2 N-m (0.2 kgf-m, 1.5 Ibf-ft) 36 N-m (3.7 kgf-m, 27 Ibf-ft)

5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft) 13 N-m (1.3 kgf-m, 10 Ibf-ft)

TOOL

HYDRAULIC BRAKE

TROUBLESHOOTING

Brake lever/pedal soft or spongy

• Air in hydraulic system

• Leaking hydraulic system

• Contaminated brake pads/disc

• Worn caliper piston seal

• Worn master cylinder piston cups

• Worn brake pads/disc

• 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

• Clogged/restricted brake system

• Sticking/worn caliper piston

• Caliper not sliding properly

• Clogged/restricted fluid passage

• Worn caliper piston seal

• Sticking/worn master cylinder piston

• Bent brake lever/pedal

Brake drags

• Contaminated brake pads/disc

• Misaligned wheel

• Clogged/restricted brake hose joint

• Warped/deformed brake disc

• Caliper not sliding properly

• Clogged/restricted brake hydraulic system

• Sticking/worn caliper piston

• Clogged master cylinder port

BEARING REPLACEMENT

DRIVER

ATTACHMENT

/PILOT

ATTACHMENT/PILOT

BEARING REPLACEMENT

Press the needle bearings out of the swingarm using the special tools and a hydraulic press.

TOOLS:

07949-3710001

07746-0010700

07746-0041000

07746-0030300

Driver

ATTACHMENT

DRIVER

i-11.5 mm 3 — 0.45 in)

I

ІСШИ NEEDLE BEARINGS

BEARING REPLACEMENT

Attachment, 24 x 26 mm Pilot, 22 mm Attachment, 30 mm I. D.

BEARING REPLACEMENT

Pack new needle bearings with grease.

Press a new needle bearing into the swingarm using the special tools and a hydraulic press as shown.

TOOLS:

Driver 07749-0010000

Attachment, 28 x 30 mm 07946-1870100

Pilot, 22 mm 07746-0041000

ASSEMBLY

WASHERS

CHAIN SLIDER

After ’07:

THRUST NEEDLE BEARING

PIVOT COLLAR

SIDE COLLAR

DUST SEAL

DUST SEAL

Apply grease to the thrust needle bearing rolling area and dust seal lips.

BEARING REPLACEMENT

Install the following:

— Washers

— Thrust needle bearings

— Pivot collars

— Dust seals

— Side collars

CHAIN SLIDER

BEARING REPLACEMENT

Install the chain slider so its hole fits over the tab on the swingarm.

SCREWS

BEARING REPLACEMENT

Clean and apply locking agent to the screw threads. Install and tighten the screws to the specified torque.

TORQUE: 4.2 N m (0.4 kgf-m, 3.1 Ibf ft)

INSTALLATION

BEARING REPLACEMENT

Apply thin coat of grease to the swingarm pivot bolt sliding surface.

Install the swingarm onto the frame.

Install the swingarm pivot bolt through the frame and swingarm pivot.

Install the washer and swingarm pivot nut.

BEARING REPLACEMENT

PIVOT NUT/WASHER

Tighten the swingarm pivot nut to the specified torque.

BOLT/NUT/WASHER

BEARING REPLACEMENT

TORQUE: 88 N m (9.0 kgf m, 65 Ibf ft)

Apply oil to the shock arm nut threads and seating surface.

’05-’07: Install the shock arm bolt, nut and washer.

After ’07: Install the shock arm bolt by aligning flat surfaces of the shock arm bolt and swingarm.

Tighten the nut to the specified torque.

TORQUE: 53 N m (5.4 kgf m, 39 Ibf ft)

BEARING REPLACEMENT

CHAIN GUIDE SLIDER

’05-’07 shown: DRIVE CHAIN

BOLTS/NUTS/COLLARS

CHAIN GUIDE ■

BEARING REPLACEMENT

Install the following:

— Drive chain (page 4-25)

— Collars (’05-’07)

— Chain guide slider

— Chain guide

Install and tighten the bolts and nuts to the specified torque.

TORQUE: 12 N m (1.2 kgf-m, 9 Ibf ft)

Do not twist the Install the rear brake caliper to the slide rail on the

brake hose, swingarm.

BRAKE CALIPER

BEARING REPLACEMENT

Install the brake hose guides and tighten the screws rDOA„c _. ,,r“-

to the specified torque. 1 BRAKE H0SE GUIDES

TORQUE: 1.2 N m (0.1 kgf m, 0.9 lbf-ft)

Install the following:

— Brake pedal (page 16-24)

— Rear wheel (page 15-13)

BEARING REPLACEMENT

SWINGARM

REMOVAL

BRAKE CALIPER

SWINGARM

Remove the following:

— Rear wheel (page 15-8)

— Brake pedal (page 16-24)

Do not disconnect Remove the rear brake caliper from the slide rail on

the hydraulic line, the swingarm.

NOTICE

Do not suspend the brake caliper from the brake hose. The brake hose may be damaged.

SWINGARM

SWINGARM

IBRAKE HOSE GUIDES

Remove the screws and brake hose guides.

Check the chain guide slider for wear or damage. Remove the following:

— Bolts

— Nuts

— Chain guide

— Chain guide slider

— Collars (’05 — ’07)

— Drive chain (page 4-25)

Raise the rear wheel off the ground by placing workstand or equivalent under the engine.

Remove the shock arm bolt, nut and washer (swing­arm side).

SWINGARMRemove the pivot nut and washer.

PIVOT NUT/WASHER

SWINGARM

Remove the pivot bolt and swingarm.

PIVOT BOLT

CHAIN SLIDER

SCREWS

SWINGARM

DISASSEMBLY

Check the chain slider for wear or damage. Remove the screws and chain slider.

BEARING

DUST SEAL

NEEDLE BEARING

SWINGARM

Remove the following:

— Side collars

— Dust seals

— Washers

— Thrust needle bearings

— Pivot collars

Check the dust seals and collars for wear, damage or fatigue.

Check the needle bearings for damage or loose fit. Check the thrust needle bearings for wear or dam­age, replace it if necessary.

Check the swingarm for cracks or damage.

Replace any damaged parts, if necessary.

WASHERS SIDE COLLAR

BEARING REPLACEMENT

SHOCK ARM NEEDLE BEARING

BEARING REPLACEMENT

Press the needle bearings (shock link side and swin­garm side) out of the shock link using the special tools and a hydraulic press.

TOOLS:

07949-3710001

07746-0010700

07746-0040500

07746-0030300

Driver

Attachment, 24 x 26 mm Pilot, 20 mm Attachment, 30 mm I. D.

Press the needle bearings (shock absorber side) out of the shock link using special tools and a hydraulic press.

DRIVER

BEARING REPLACEMENT

TOOLS:

07749-0010000

07746-0010700

07746-0041400

07746-0030300

Driver

Attachment, 24 x 26 mm Pilot, 19 mm Attachment, 30 mm I. D.

DRIVER

r- NEEDLE BEARINGS

6.0 — 6.5 mm (0.24-0.26 in)

NEEDLE BEARINGS

3.0-3.2 mm (0.12-0.13 in)

BEARING REPLACEMENT

Press the needle bearing into the shock arm with the marked side facing out.

07749-0010000

07746-0010700

07746-0040500

BEARING REPLACEMENT

4.4- 4.7 mm (0.17-0.19 in)

NEEDLE BEARINGS

Press the needle beanng into the shock arm with the marked side facing out.

07749-0010000

07746-0010700

07746-0040500

Press the needle bearing into the shock arm with the marked side facing out.

&

07749-0010000

07746-0010700

07746-0041400

Pack a new needle bearing with grease.

Press a new needle bearing into the shock absorber side pivot with the special tools and a hydraulic press so that the needle bearing surface is 3.0 — 3.2 mm (0.12 — 0.13 in) below the end of the shock arm surface.

Pack new needle bearings with grease.

Press new needle bearings into the swingarm side pivot with the special tools and a hydraulic press so that the needle bearing surface is 4.4 — 4.7 mm (0.17 -0.19 in) below the end of the shock arm surface.

Pack new needle bearings with grease.

Press new needle bearings into the shock link side pivot with the special tools and a hydraulic press so that the needle bearing surface is 6.0 — 6.5 mm (0.24 — 0.26 in) below the end of the shock arm surface.

TOOLS:

Driver

Attachment, 24 x 26 mm Pilot, 20 mm

TOOLS:

Driver

Attachment, 24 x 26 mm Pilot, 20 mm

TOOLS:

Driver

Attachment, 24 x 26 mm Pilot, 19 mm

I

SHOCK LINK NEEDLE BEARING

Remove the needle bearing from the shock link.

NEEDLE BEARING

BEARING REPLACEMENT

SHOCK LINK

DRIVER

BEARING REPLACEMENT

4.4-4.7 mm

BEARING REPLACEMENT

NEEDLE —5ЩШШ BEARINGS

Press the needle bearing into the shock link with the marked side facing out.

ATTACHMENT/PILOT

Pack new needle bearings with grease.

Press new needle bearings into the pivot with the special tools and a hydraulic press so that the nee­dle bearing surface is 4.4 — 4.7 mm (0.17 — 0.19 in) below the end of the shock arm surface.

TOOLS:

Driver 07749-0010000

Attachment, 24 x 26 mm 07746-0010700

Pilot, 20 mm 07746-0040500

INSTALLATION

SIDE COLLARS

DUST SEALS

WASHERS

PIVOT COLLAR

BEARING REPLACEMENT

Apply multi-purpose grease NLGI No.2 (molybde­num disulfide additive) to the shock arm, dust seal lips, side collar seating surface and needle bearing rolling area.

• Make sure the needle bearing rollers are in posi­tion before installing.

Number of needle rollers:

Shock link side: 32 Swingarm side: 32 Shock absorber side: 27

Install the dust seals and washers (shock link side).

Install the dust seals to the shock arm (swingarm side).

PIVOT COLLARS

SIDE COLLARS

BEARING REPLACEMENT

Install the pivot collar, side collars and dust seals (shock absorber side).

Install the pivot collars and side collars to the shock arm (swingarm side, shock link side).

BEARING REPLACEMENTApply multi-purpose grease NLGI No.2 (molybde­num disulfide additive) to the dust seal lips, side collar seating surface and needle bearing rolling area.

BEARING REPLACEMENT

Install the dust seals, pivot collar and side collars.

• Make sure the needle bearing rollers are in posi­tion before installing.

Number of needle rollers: 32

’05 — ’07 shown:

BOLT/NUT/WASHER

RDI т/Ml IT/WAQHPR л (FRAME SIDE) M

(SWINGARM SIDE) SHOCK ARM

BOLT/NUT/WASHER (SHOCK LINK SIDE)

BEARING REPLACEMENT

SHOCK LINK

LOWER BOLT/NUT

BOLT/NUT/WASHER (SWINGARM SIDE)

Apply oil to the shock arm and shock link nut threads and flange surface.

Loosely install the following:

— Shock link

— Shock link bolt/nut/washer (frame side)

— Shock arm

— Shock arm bolt/nut/washer (swingarm side) NOTE:

After ’07: Align the flat surfaces of the shock arm bolt and swingarm.

— Shock arm bolt/nut/washer (shock link side)

Install the shock absorber lower mounting bolt aligning the flat side of the bolt with the stopper on the shock absorber.

Tighten all nuts to the specified torque.

TORQUE:

Shock link nut (frame side):

53 N m (5.4 kgf-m, 39 Ibf-ft)

Shock arm nut (swingarm side):

53 N-m (5.4 kgf-m, 39 Ibf ft)

Shock arm nut (shock link side):

53 N-m (5.4 kgf-m, 39 Ibf-ft)

Shock absorber lower mounting nut:

44 N-m (4.5 kgf-m, 32 Ibf-ft)

’05 — ’07:

BOLT/NUT/WASHER (FRAME SIDE)

SHOCK LINK

LOWER

BOLT/NUT

BEARING REPLACEMENT

Ish

BOLT/NUT/WASHER

SHOCK ARM

LOWER

BOLT/NUT

SHOCK ARM

BOLT/NUT/WASHER

BOLT/NUT/WASHER^ SIDE) I

Install the drive chain roller with the mark facing out.

WASHER

COTTER PIN

BEARING REPLACEMENT

Tighten the nut to the specified torque.

TORQUE: 12 N m (1.2 kgf m, 9 Ibf ft)

Install the step bracket assembly and mounting bolts.

Tighten the upper mounting bolt to the specified torque.

TORQUE: 55 N m (5.6 kgf-m, 41 lbf-ft)

Tighten the lower mounting bolt to the specified torque.

TORQUE: 30 N m (3.1 kgf m, 22 lbf-ft)

Install the left step, spring, joint pin, washer and new cotter pin securely as shown.