Warning! Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In the case of accidental contact, wash the affected area thoroughly with plenty of running water.
Caution! On handing over the motorcycle after changing the brake pads, inform the customer that the front brake must be used gently for the first 100 km to allow the pads to bed in completely.
Checking front brake pad wear
Look through the slot in the caliper clip (1) to make sure the groove in the brake pad friction material (2) is still visible.
Caution! If either of the pads is worn, both pads must be renewed as a set.
Change the brake pads as follows.
Remove the calipers (Removal of the front brake system).
Remove the cotter pin (3) from the pad retaining pin.
Force the caliper pistons back into their bores by forcing the old brake pads apart.
Withdraw the pad retaining pins (4) from the outside.
Remove the clip (1) from between the two caliper halves.
Remove the worn pads (2).
Note: Change pads that have a shiny or "vitrified" appearance.
Insert the new pads and clip (1). Slide in the pad retaining pin (4) and secure it in position with the cotter pin (3).
Operate the brake lever repeatedly so that the pads are firmly bedded in against the disc by the force of the brake fluid.
Check that the brake fluid level in the master cylinder reservoir is above the MIN mark. If necessary, top up as follows. Turn the handlebar so that the reservoir is level.
Unscrew the two crosshead screws (6) and remove the reservoir cover (5).
Remove the inner membrane from the reservoir.
Top up to maximum level with the specified brake fluid (Fuel, lubricants and other fluids).
Refit all previously removed components.
Checking rear brake pad wear
Check through the slot between the two caliper halves that there is at least 1 mm of friction material on the pads.
Caution! If either of the pads is worn, both pads must be renewed as a set.
Note: Change pads that have a shiny or "vitrified" appearance.
Insert the new pads and clip (3). Slide in the pad retaining pin (2) and secure it in position with the circlip (1).
Operate the brake pedal repeatedly so that the pads are bedded in against the disc by the force of the brake fluid.
Check that the brake fluid level in the reservoir (4) is between the MIN and MAX marks. If not, unscrew the reservoir cover (4) and top up with the recommended brake fluid.
Note: If it proves difficult to change the brake pads, first remove the caliper from the motorcycle (Removal of the rear brake system).
Warning! As the brake calipers are components of vital importance to the safety of the motorcycle, refer to the instructions in Removal of the front brake system and Removal of the rear brake system, and in particular, on reassembly, remember to tighten the caliper screws to the specified torque (Frame torque settings).