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}.

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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.

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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)

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