Monthly Archives: Март 2014

REAR MASTER CYLINDER

REAR MASTER CYLINDER

REMOVAL

Drain the rear brake hydraulic system (page 16-6). Remove the brake pedal (page 16-24).

When removing the Remove the brake hose oil bolt, sealing washers brake hose oil bolt, and brake hose eyelet.

cover the end of the hose to prevent contamination.

Secure the hose to prevent fluid from leaking out.

Remove the master cylinder mounting bolts and rear master cylinder.

DISASSEMBLY

BOOT

REAR MASTER CYLINDER

Remove the boot.

Remove the snap ring from the master cylinder body using the special tool as shown.

TOOL:

Snap ring pliers 07914-SA50001

Remove the push rod, master piston and spring.

INSPECTION

SPRING

PUSH ROD

MASTER PISTON

REAR MASTER CYLINDER

Clean the inside of the cylinder with brake fluid.

Check the piston boot, primary cup and secondary cup for fatigue or damage.

Check the master cylinder and piston for abnormal scratches.

Measure the master cylinder I. D. SERVICE LIMIT: 9.575 mm (0.3770 in)

REAR MASTER CYLINDER

Measure the master piston O. D. SERVICE LIMIT: 9.465 mm (0.3726 in)

ASSEMBLY

Replace the piston, cups, spring, snap ring and boot as a set; do not substitute individual parts.

SPRING

Dip the piston and master cylinder I. D. in brake fluid.

MASTER PISTON

PUSH ROD

MASTER CYLINDER

REAR MASTER CYLINDER

Install the spring to the piston.

When installing the Install the piston assembly into the master cylinder. cups, do notallow Apply silicone grease to the rounded surface of the

the lips to turn push rod. inside out.


Adjust the brake pedal to the desired height by loos­ening the lock nut and turning the adjuster.

STANDARD LENGTH: 79.6 mm (3.13 in)

Tighten the lock nut to the specified torque. TORQUE: 5.9 N m (0.6 kgf m, 4.4 Ibf ft)

Install the push rod into the master cylinder. Install the snap ring using the special tool.

TOOL:

Snap ring plier 07914-SA50001

Apply silicone grease to the boot fitting area. Install the boot.

INSTALLATION

Install the master cylinder and tighten the mounting bolts to the specified torque.

TORQUE: 13 N m (1.3 kgf m, 10 Ibf-ft)

SNAP RING

BOOT

ADJUSTER

REAR MASTER CYLINDER

Be certain the snap ring is firmly seated in the groove

LOCK NUT

79.6 mm (3.13 in)

REAR MASTER CYLINDER

BOLTS

REAR MASTER CYLINDER

MASTER CYLINDER

OIL BOLT

Install the brake hose with the oil bolt and new seal­ing washers.

Push the eyelet joint against the stopper, then tighten the brake hose oil bolt to the specified torque.

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

STOPPER

Install the brake pedal (page 16-24).

Fill and bleed the rear brake hydraulic system (page 16-7).

SEALING WASHERS /

Remove the caliper mounting bolts and then remove the caliper and bracket as an assembly.

DISASSEMBLY

Remove the caliper bracket from the caliper body.

Remove the brake pad spring from the caliper body. Remove the brake pad retainer from the caliper bracket.

Remove the caliper pin boot and bracket pin boot.

BRAKE HOSE

BOLT

REAR MASTER CYLINDER

SEALING WASHERS

*1144

REAR MASTER CYLINDER

CALIPER/BRACKET ASSEMBLY % ■v

CALIPER RETAINER

BRACKET

BOOTS

REAR MASTER CYLINDER

FRONT MASTER CYLINDER

REMOVAL

FRONT MASTER CYLINDER

SEALING WASHERS

OIL BOLT

Drain the front brake hydraulic system (page 16-6).

Remove the brake hose oi and brake hose eyelet.

bolt, sealing washers

When removing the brake hose oil bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out.


Remove the bolts, holder and master cylinder assembly.

MASTER CYLINDER

FRONT MASTER CYLINDER

HOLDER

BOLTS

DISASSEMBLY

DUST COVER PIVOT BOLT/NUT

FRONT MASTER CYLINDER

BRAKE LEVER

Remove the dust cover.

Remove the pivot bolt/nut and brake lever assem­bly.

Remove the boot.

BOOT

FRONT MASTER CYLINDER

Remove the snap ring from the master cylinder body using the special tool as shown.

TOOL:

Snap ring pliers 07914-SA50001

Remove the washer, master piston and spring.

WASHER

INSPECTION

SPRING

FRONT MASTER CYLINDER

PISTON

Clean the inside of the cylinder and reservoir with brake fluid.

Check the piston boot, primary cup and secondary cup for fatigue or damage.

Check the master cylinder and piston for abnormal scratches.

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Measure the master cylinder I. D. SERVICE LIMIT: 11.050 mm (0.4350 in)

FRONT MASTER CYLINDER

Measure the master piston O. D. SERVICE LIMIT: 10.840 mm (0.4268 in)

FRONT MASTER CYLINDER

ASSEMBLY

Replace the piston, cups, spring, snap ring and boot as a set; do not substitute individual parts.

PISTON

WASHER

FRONT MASTER CYLINDER

Dip the piston and master cylinder I. D. in brake fluid.

Install the spring to the piston.

When installing the cups, do not allow the lips to turn inside out

Install the piston assembly into the master cylinder.

Install the snap ring using the special tool.

TOOL:

Snap ring pliers 07914-SA50001

Apply silicone grease to the inside of the boot. Install the boot to the master cylinder.

Install the brake lever.

Apply silicone grease to the pivot bolt sliding sur­face.

Install and tighten the pivot bolt to the specified torque.

TORQUE: 1.0 N m (0.1 kgf m, 0.7 lbf-ft)

Tighten the pivot nut to the specified torque. TORQUE: 5.9 N-m (0.6 kgf m, 4.4 lbf-ft)

Install the dust cover.

INSTALLATION

Place the master cylinder assembly on the handle­bar.

Align the end of the master cylinder with the paint mark on the handlebar.

Install the master cylinder holder with the "UP" mark facing up.

Tighten the upper bolt first, then the lower bolt to the specified torque.

TORQUE: 9.9 N m (1.0 kgf m, 7.3 lbf-ft)

SNAP RING

FRONT MASTER CYLINDER

Be certain the snap ring is firmly seated in the groove.

BOOT

DUST COVER PIVOT BOLT/ NUT

FRONT MASTER CYLINDER

BRAKE LEVER

MASTER CYLINDER PAINT MARK

HOLDER

BOLTS

FRONT MASTER CYLINDER

FRONT MASTER CYLINDERAlign the brake hose eyelet between the stoppers. Install the brake hose eyelet with the oil bolt and new sealing washers.

BRAKE HOSE

OIL BOLT

Tighten the brake hose oil bolt to the specified torque.

TORQUE: 34 N m (3.5 kgf m, 25 Ibf ft)

Fill and bleed the front brake hydraulic system (page 16-7).

SEALING WASHERS

BRAKE PAD/DISC

BRAKE PAD REPLACEMENT

BOLTS

DISC COVER

For front brake, remove the bolts and brake disc cover.

Push the caliper pistons all the way in to allow installation of new brake pads.

NOTE

• Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise.

For the front brake, remove the pad pin plug and pad pin.

For the rear brake, remove the pad pin.

PAD PIN PLUG

BRAKE PADS

Remove the brake pads.

Install new brake pads to the pad retainer securely.

NOTE:

• Always replace the brake pads in pairs to assure even disc pressure.

• A contaminated brake disc or pad reduces stop­ping power.

• Discard contaminated pads and clean a contami­nated disc with a high quality brake decreasing agent.

BRAKE PADS *3»

BRAKE PAD/DISCFor the front brake, push the brake pads against the pad spring, then install the pad pin.

Tighten the pad pin to the specified torque.

TORQUE: 18 N m (1.8 kgf m, 13 Ibf ft)

Install and tighten the pad pin plug to the specified torque.

PAD PIN PLUG

TORQUE: 2 N m (0.2 kgf m, 1.5 Ibf-ft)

DISC COVER

BOLTS

Install the front brake disc cover and tighten the bolts specified torque.

TORQUE: 13 N m (1.3 kgf m, 10 Ibf-ft)

For the rear brake, install a new O-ring into the pad pin groove.

Install and tighten the pad pin to the specified torque.

TORQUE: 18 N m (1.8 kgf m, 13 Ibf ft)

Operate the brake lever or pedal to seat the caliper piston against the pads.

BRAKE PAD/DISC

05 — ’07 shown

BRAKE DISC INSPECTION

• Remove the front brake disc cover (page 16-10).

Visually inspect the brake disc for damage or cracks.

Measure the brake disc thickness with a microme­ter.

SERVICE LIMITS:

FRONT: 2.5 mm (0.10 in)

REAR: 3.5 mm (0.14 in)

Replace the brake disc if the smallest measurement is less than the service limit.

(

Measure the brake disc warpage with a dial indica­tor.

p05 — ’07

BRAKE PAD/DISC

SERVICE LIMIT: 0.15 mm (0.006 in)

Check the wheel bearings for excessive play, if the warpage exceeds the service limit.

Replace the brake disc if the wheel bearings are nor­mal.

BRAKE FLUID REPLACEMENT/AIR BLEEDING

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

• Once the hydraulic system has been opened, or if the brake feels spongy the system must be bled.

• When using a commercially available brake bleeder, follow the manufacturer’s operating instruction.

BRAKE FLUID DRAINING

Do not allow foreign material to enter the system. Avoid spilling fluid on plastic or rubber parts. Place a rag over these parts whenever the system is serviced

SCREWS

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Check the master cylinder parallel to the ground, before removing the reservoir cover.

For the front brake, remove the screws, reservoir cover and diaphragm.

For the rear brake, remove the bolts, reservoir cover, set plate and diaphragm.

For the rear brake, remove the bolts and rear brake caliper guard.

Connect a bleed hose to the bleed valve.

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Loosen the bleed valve and pump the brake lever (pedal}.

#

Stop operating the brake when no more fluid flows out of the bleed valve.

BRAKE FLUID FILLING/AIR BLEEDING

UPPER LEVEL

FRONT MASTER CYLINDER REAR MASTER CYLINDER

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Do not mix different Fill the master cylinder with DOT 4 brake fluid to the

types of fluid since upper level. they are not compatible.

Do not allow foreign material to enter the system.

u

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Connect a commercially available brake bleeder to the bleed valve.

Operate the brake bleeder and loosen the bleed valve. If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low.

BRAKE FLUID REPLACEMENT/AIR BLEEDING

If air enters the bleeder from around the bleed valve threads, seal the threads with teflon tape.

Perform the bleeding procedure until the system is completely flushed/bled.

Close the bleed valve and operate the brake lever or pedal.

If it still feels spongy, bleed the system again.

REAR CALIPER

BRAKE FLUID REPLACEMENT/AIR BLEEDING

BRAKE FLUID REPLACEMENT/AIR BLEEDING

BLEED VALVE

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Do not release the lever or pedal until the bleed valve has been closed.

1. Pump the brake lever or pedal several times, then squeeze the brake lever or pedal all the way and loosen the bleed valve 1/2 of a turn.

Wait several seconds and close the bleed valve.

2. Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel.

3. Repeat steps 1-2 until there are no air bubbles in the bleed hose.

After bleeding air completely, tighten the bleed valves to the specified torque.

TORQUE: 5.4 N m (0.6 kgf m, 4.0 Ibf ft)

If a brake bleeder is not available, perform the fol­lowing procedure.

Connect a clear bleed hose to the bleed valve. Pressurize the system with the lever or pedal until there are no air bubbles in the fluid flowing out of the small hole in the reservoir and lever or pedal resistance is felt.

For the rear brake, install the brake caliper guard and tighten the bolts securely.

BRAKE FLUID REPLACEMENT/AIR BLEEDING

CALIPER GUARD

BOLTS

UPPER LEVEL

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Fill the reservoir with DOT 4 brake fluid to the top of the upper level.

FRONT:

RESERVOIR COVER/DIAPHRAGM

SCREWS

BRAKE FLUID REPLACEMENT/AIR BLEEDING

Install the diaphragm and reservoir cover.

Tighten the reservoir cover screws to the specified torque.

TORQUE: 1.0 N m (0.1 kgf m, 0.7 Ibf ft)

BRAKE FLUID REPLACEMENT/AIR BLEEDING

BOLTS

DIAPHRAGM

REAR:

Straighten the diaphragm and install it to the rear master cylinder.

Check the diaphragm installation as shown.

Install the set plate and reservoir cover.

Tighten the reservoir cover bolts to the specified torque.

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