Inspection
Brake pads
Warning! Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury.
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
See Figure 1-53. Replace brake pads if thickness of brake pad friction material (3) is worn to 0.040 in (1.02 mm) or less. Always replace both pads in a caliper as a set. See 1.17 BRAKE PADS AND DISCS: XR 1200X, Brake Pad Replacement: Front or 1.17 BRAKE PADS AND DISCS: XR 1200X, Brake Pad Replacement: Rear.
Figure 1-53. Brake Pad MIN Thickness: XR 1200X: 1. Front, from below; 2. Rear, from above; 3. MIN thickness
When checking the brake pads and discs, inspect the brake hoses for correct routing and any signs of damage or leakage.
Brake disc thickness, lateral runout and warpage
See Figure 1-54. The minimum brake disc (4) thickness is stamped on the side of the disc. Replace disc if worn past minimum thickness or badly scored.
Figure 1-54. Brake Pad Inspection (front brake shown): 1. Friction material thickness; 2. Pad backing plate; 3. Friction material; 4. Brake disc
Maximum brake disc lateral runout and warpage is 0.008 in (0.2 mm) when measured near the outside diameter.
To replace front brake disc(s), see 2.5 WHEELS, Front Wheel.
To replace rear brake disc, see 2.5 WHEELS, Rear Wheel.
Brake pad replacement: front
| FASTENER | TORQUE VALUE | |
| Brake pad pin | 131-173 in·lbs | 14.8-19.6 Nm |
| Brake master cylinder, front, reservoir cover screws | 9-17 in·lbs | 1.0-2.0 Nm |
Removal
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Notes:
- If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
- Cover handlebar switches with a shop towel before adding brake fluid to front master cylinder reservoir. Spilling brake fluid on handlebar switches may render them inoperative.
1. Turn handlebar to level the front master cylinder reservoir.
2. See Figure 1-55. Remove two screws (5), reservoir cover (4), diaphragm plate (3) and diaphragm (2) from master cylinder reservoir (1).
Figure 1-55. Front Brake Master Cylinder Cover Assembly (typical): 1. Front brake master cylinder assembly; 2. Diaphragm; 3. Diaphragm plate; 4. Reservoir cover; 5. Captive screw (2)
Note. As the pistons are pushed back into the caliper, fluid level may rise higher than fluid level mark at about 1/4 in (6.35 mm) below top of reservoir. Remove fluid as necessary to prevent overflow.
3. Wrap a shop towel around the master cylinder reservoir to contain any brake fluid spills.
4. Pry between the brake pads and brake disc to force all caliper pistons back into their bores. Do not to scratch the rotor or cause warpage.
5. See Figure 1-56. Remove pad pins (1).
6. Remove pad spring (2) and brake pads through opening in caliper assembly.
Note. The pad pins are manufactured with a relief near the center of their length, where the pad spring touches. Do not use this area as a measurement point to determine pad pin wear.
7. Inspect pad pin for grooving and wear. Measure pad pin diameter in an unworn area and in the area of any grooving or wear. If wear exceeds 0.011 in (0.28 mm), replace pin.
8. Inspect pad spring for wear or cracks. Replace if necessary.
Installation
Note. See Figure 1-57. When replacing front brake pads, make sure pad spring is installed with the arrow and word UP (2) pointing up and captured by both pad pins (3).
Figure 1-57. Front Caliper Pad Spring Orientation: 1. Banjo bolt hole; 2. Arrow and word "UP"; 3. Pad pins (2)
1. See Figure 1-56. Install new outer brake pad and pad spring. Make sure friction material faces brake disc.
Figure 1-56. Front Caliper Assembly: XR 1200X: 1. Pad pins; 2. Pad spring
Note. If pad pin does not fit, check the following:
- You are using the correct set of pads.
- Pad spring orientation must match Figure 1-57.
- Push pads tight up against pad spring before pad pins are installed.
2. While holding new outer pad in place, insert pad pins through holes in tabs of pad and into pad spring.
3. Install new inner brake pad, making sure friction material faces brake disc.
4. Push pad pins through holes in tabs of inner pad and into holes in caliper housing.
5. Tighten pad pins to 131-173 in·lbs (14.8-19.6 Nm).
Warning! After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.
6. Pump brake lever to move pistons out until they contact outside brake pad. Verify piston location against pad.
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
7. See Figure 1-58. Check brake fluid level in master cylinder. Add enough DOT 4 BRAKE FLUID to reservoir to bring fluid level even with ridge (1) cast into inside of reservoir, about 1/4 in (6.35 mm) below top edge.
Figure 1-58. Filling Front Master Cylinder Reservoir (typical): 1. Cast-in ridge; 2. Sight glass
8. See Figure 1-55. Install diaphragm (2), diaphragm plate (3), reservoir cover (4) and screws (5) on front brake master cylinder reservoir. Tighten screws to 9-17 in·lbs (1.0-2.0 Nm).
Warning! After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury.
9. Test brake system.
- a. Turn ignition switch ON. Pump brake lever to verify operation of the stop lamp.
- b. Test ride the motorcycle at low speed. If the brakes feel spongy, bleed the system. See 2.17 BLEEDING BRAKES.
Note. Avoid making hard stops for the first 100 mi (160 km). This allows the new pads to become conditioned to the brake discs.
Brake pad replacement: rear
| FASTENER | TORQUE VALUE | |
| Brake pad pin | 131-173 in·lbs | 14.8-19.6 Nm |
| Brake pad pin plug | 18-25 in·lbs | 2.0-2.9 Nm |
Removal
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Notes:
- Do not remove rear caliper from mounting bracket unless caliper mounting pins and boots require service. Removing caliper from mounting bracket unnecessarily increases the risk of contaminants falling into caliper boots and bushings. These contaminants could damage caliper during vehicle operation.
- See Figure 1-60. It is not required or recommended to remove or loosen the caliper mounting fasteners (2).
- It is not necessary or recommended to remove the rear brake caliper from the caliper mounting bracket to replace pads.
- If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. Place motorcycle in an upright, level position.
2. Remove rear master cylinder reservoir cover.
3. Place a suitable container under the rear master cylinder to catch any fluid that may overflow.
Note. The fluid level can rise above the upper fluid level in the reservoir. Remove fluid as necessary.
4. Press against the outside of the brake caliper body to push
the caliper piston back into its bore, forcing fluid back to the reservoir.
Note. See Figure 1-59. Verify that pad spring is installed before installing new pads.
Figure 1-59. Rear Caliper Pad Spring
Note. Left shock absorber is disconnected from rear fork for clarity of photograph. Pad replacement does not require the shock be disconnected.
5. See Figure 1-60. Remove pad pin plug (1).
Figure 1-60. Rear caliper assembly: XR 1200X: 1. Pad pin plug; 2. Mounting fasteners
6. Loosen, but do not remove, brake pad pin (metric).
7. Pull pad pin part way out until inner pad drops free. Remove pad and note the pad's original orientation for replacement purposes.
8. Continue to remove pad pin until outer pad drops free.
9. Inspect pad pin for grooving and wear.
10. Measure pad pin diameter in an unworn area and then in the area of any grooving or wear. If wear exceeds 0.011 in (0.28 mm), replace pin.
Installation
Note. The caliper and mounting bracket are shown removed for clarity of photograph. Removal is not required to replace brake pads.
1. See Figure 1-61. Install new outside brake pad using the same orientation as pad previously removed. Make sure front mounting tab (3) is seated in slot (6) in caliper mounting bracket and pad friction material faces brake disc.
Figure 1-61. Rear Brake Pads: XR 1200X: 1. Outside brake pad; 2. Inside brake pad; 3. Front mounting tab; 4. Pad pin hole; 5. Rear caliper mounting bracket; 6. Slot
2. Install pad pin into caliper and through outer pad.
3. Position inner pad and continue to install pad pin while pressing brake pads firmly up against pad spring. Tighten pad pin to 131-173 in·lbs (14.8-19.6 Nm).
Note. If pad pin does not fit, check the following:
- The part number of the pads.
- See Figure 1-59. Check pad spring orientation.
- See Figure 1-61. Pad front mounting tabs (3) must be fully seated in mounting bracket slot (6).
- Push the pads tight up against pad spring before pad pin is installed.
4. Install pad pin plug. Tighten to 18-25 in·lbs (2.0-2.9 Nm).
Warning! After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.
5. Pump brake pedal to move piston out until it contacts outside brake pad. Verify piston location against pad.
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Note. Position rear brake master cylinder reservoir level when filling or checking fluid level.
6. Check brake fluid level in master cylinder reservoir. If necessary, add DOT 4 BRAKE FLUID to reservoir until fluid reaches upper fluid level.
7. Replace reservoir cover.
Warning! After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury.
8. Test brake system.
- a. Turn ignition switch ON. Pump brake pedal to verify operation of the stop lamp.
- b. Test ride motorcycle at low speed. If the brakes feel spongy, bleed the system. See 2.17 BLEEDING BRAKES.
Note. Avoid making hard stops for the first 100 mi (160 km). This allows the new pads to become conditioned to the brake discs.