Service information — hydraulic brake General Caution: 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...
Troubleshooting — hydraulic brake Brake lever/pedal soft or spongy Air in hydraulic system Low brake fluid level Leaking hydraulic system Clogged fluid passage Contaminated brake pad/disc Worn caliper piston seals Worn master cylinder piston cups Worn brake pad/disc Contaminated...
Brake fluid replacement/air bleeding Brake fluid draining Front brake: Turn the handlebar until the reservoir is parallel to the ground. Remove the following: Screws [1] Reservoir cap [2] Set plate [3] Diaphragm [4] Rear brake: Turn the handlebar until the reservoir is parallel to the...
Brake pad/disc — installation, inspection Note: Always replace the brake pads in pairs to assure even disc pressure. Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise. Front brake pad removal/installation Do not operate the brake...
Front master cylinder — removal, installation, disassembly, inspection and assembly Removal/installation When removing the oil bolt, cover the end of the brake hose to prevent contamination. Drain the brake fluid from the front brake line hydraulic system (page 19-6). Disconnect the brake light switch connectors [1]. Remove the...
Rear brake pedal — removal and installation Removal/installation Note: Align the brake pedal slit with the middle arm punch mark. Always replace the cotter pin with a new one. Always replace the dust seal with a new one. Apply grease to the dust seal lips. Apply grease to the middle arm pivot...
Rear master cylinder — removal, installation, disassembly, inspection and assembly Removal/installation Drain the rear brake line hydraulic system (page 19-6). Remove the bolt [1] and heel guard [2]. Avoid spilling fluid on painted, plastic, or rubber parts. Remove the oil bolt [1], sealing washers [2] and brake hose [3]. Remove...
Front brake caliper — removal, installation, disassembly, inspection and assembly Removal/installation Avoid spilling fluid on painted, plastic, or rubber parts. Place a shop towel over these parts whenever the system is serviced. Drain the brake fluid from the front brake line hydraulic system (page 19-6). Remove the oil bolt...
Rear brake caliper — removal, installation, disassembly, inspection and assembly Removal/installation Avoid spilling fluid on painted, plastic, or rubber parts. Place a shop towel over these parts whenever the system is serviced. Drain the brake fluid from the pedal brake line hydraulic system (page 19-6). Remove the oil bolt...
Parking brake lever (CRF1000D) — removal, installation, disassembly and assembly Removal Remove the knuckle guard (page 2-5). Remove the rearview mirror (page 17-4). Disconnect the parking brake switch connectors [1]. Remove the bolts [1], holder [2], and parking brake lever assembly [3]. Loosen the lock nut [4] and disconnect...