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

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