Warning: The dust created by the brake system may contain asbestos, which is harmful to your health. Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use clean brake fluid, brake cleaner or denatured alcohol only.
Note: On models with twin front disc brakes, always renew both sets of pads in the front calipers at the same time.
Front brake pads - XL600V-H to P (1987 to 1993) models and XRV750-L to N (1990 to 1992) models
1. On XRV models, remove the fork guards (see Chapter 8).
2. To allow for the increased friction material thickness of new pads, push the brake caliper against the disc so that the piston is forced back into the caliper (see illustration 2.31). It may be necessary to remove the master cylinder reservoir cover and diaphragm and siphon out some fluid. If the pistons are difficult to push back, attach a length of clear hose to the bleed valve and place the open end in a suitable container, then open the valve and try again. Take great care not to draw any air into the system. If in doubt, bleed the brakes afterwards (see Section 10).
3. Unscrew the bolt securing the brake hose in the clamp on the front fork and release it, noting how it fits (see illustration).
2.3. Release the brake hose from the clamp
4. On XL600V-H to L (1987 to 1990) models, unscrew the pad pin retainer bolt and remove the retainer, noting how it fits (see illustration). On XL600V-M to P (1991 to 1993) models and XRV750 models, unscrew the pad retaining pin plugs, then slacken the pad retaining pins (see illustration).
2.4a. Front brake caliper - XL600V-H to P (1987 to 1993) models: 1. Pad retaining pins; 2. Pad pin retainer and bolt; 3. Brake pads; 4. Pad spring; 5. Bleed valve and cap; 6. Slider pins; 7. Rubber boots; 8. Collar; 9. Pistons; 10. Piston seals; 11. Dust seals; 12. Pad guide; 13. Caliper bracket
2.4b. Front brake caliper - XRV750-L to N (1990 to 1992) models: 1. Pad pin plug - 2 off; 2. Pad retaining pin - 2 off; 3. Brake pads; 4. Pad spring; 5. Caliper body; 6. Bleed valve and cap; 7. Pistons seals; 8. Dust seals; 9. Pistons; 10. Slider pins; 11. Rubber boots; 12. Caliper bracket; 13. Pad guide
5. Unscrew the caliper bracket mounting bolts and slide the caliper assembly off the disc. Remove the pad retaining pins and remove the pads, noting how they fit. Note the pad spring in the top of caliper and the pad guide on the caliper bracket and remove them if required for cleaning or replacement, noting how they fit.
6. Inspect the surface of each pad for contamination and check whether the friction material has worn beyond its service limit (see Chapter 1, Section 3). If either pad is worn to or beyond the service limit, is fouled with oil or grease, or is heavily scored or damaged by dirt and debris the pads must be renewed (see Note). Note that it is extremely difficult to effectively degrease the friction material; if the pads are contaminated In any way new ones must be fitted.
7. If the pads are in good condition clean them carefully, using a fine wire brush which is completely free of oil and grease to remove all traces of road dirt and corrosion. Using a pointed instrument, clean out the grooves in the friction material and dig out any embedded particles of foreign matter. Any areas of glazing may be removed using emery cloth. Spray with a dedicated brake cleaner to remove any dust. It Is also worth spraying the inside of the caliper to remove any dust there, and also to spray the discs.
8. Check the condition of the brake disc (see Section 3).
9. Remove all traces of corrosion from the pad pins and check they are not bent or damaged. Smear the pins, the backs of the pads and the leading and trailing edges of the backing material with copper-based grease, making sure that none gets on the friction material.
10. Make sure that the pad spring and pad guide are correctly fitted. Fit the pads into the caliper so that the friction material of each pad faces the disc. Make sure the leading edges locate correctly against the guide on the bracket. Press the pads up against the pad spring to align the holes and insert the pad pins. On XL600V-M to P (1991 to 1993) models and XRV750, tighten the pins finger-tight.
11. Slide the caliper onto the disc making sure the pads locate on each side. Apply a suitable non-permanent thread-locking compound to the mounting bolts and tighten them securely.
12. On XL600V-H to L (1987 to 1990) models, fit the retainer onto the pins and secure it with Its bolt. On XL600V-M to P (1991 to 1993) models and XRV750, tighten the pad pins securely, then fit the plugs - it Is advisable to apply some copper or silicone grease to their threads. Where twin discs are fitted, renew the pads in the other caliper.
13. Fit the brake hose into its clamp on the front fork and secure it with the bolt (see illustration 2.3).
14. Top up the master cylinder reservoir if necessary (see Daily (pre-ride) checks).
15. Operate the brake lever several times to bring the pads into contact with the disc, Check the operation of the brake before riding the motorcycle.
Front brake pads - XL600V-R to X (1994 to 1999) models, XL650V models and XRV750-P models onwards (1993-on)
16. On XRV models, remove the fork guards (see Chapter 8).
17. To allow for the increased friction material thickness of new pads, push the brake caliper against the disc so that the piston is forced back into the caliper (see illustration 2.31). It may be necessary to remove the master cylinder reservoir cover and diaphragm and siphon out some fluid. If the pistons are difficult to push back, attach a length of clear hose to the bleed valve and place the open end in a suitable container, then open the valve and try again. Take great care not to draw any air into the system. If in doubt, bleed the brakes afterwards (see Section 9).
18. Unscrew Ihe pad retaining pin plug, then unscrew the pad retaining pin (see illustrations). Withdraw the pin and slide the pads down out of the caliper (see illustrations).
2.18a. Unscrew the brake pad retaining pin plug...
2.18b ...then unscrew the retaining pin
2.18c ...and draw the pads out of the caliper
2.18d Front brake caliper - XRV750-P models onward (1993-on): 1. Pad pin plug; 2. Pad retaining pin; 3. Brake pads; 4. Pad spring; 5. Bleed valve; 6. Dust seals; 7. Slider pins; 8. Caliper bracket; 9. Pad guide; 10. Pistons; 11. Dust seals; 12. Fluid seals
19. Refer to Steps 5. 6, 7 and 8 above.
20. If fitted, make sure the shim on the back of each pad is correctly located (see illustration). Fit the pads into the caliper so that the friction material of each pad faces the disc, making sure the leading edges locate correctly against the guide (see illustrations). Press the pads up against the pad spring to align the holes and insert the pad pin. then tighten it securely (see illustration). Install the pad pin plug - it is advisable to apply some copper or silicone grease to its threads (see illustration 2.18a). Repeat the pad renewal procedure on the other caliper.
2.20a. Make sure the shim is correctly fitted
2.20b. Slide the pads up into the caliper...
2.20c ...making sure they locate correctly (arrow)
2.20d. Press the pad up against the spring and insert the retaining pin
21. Top up the master cylinder reservoir if necessary (see Daily (pre-ride) checks).
22. Operate the brake lever several times to bring the pads into contact with the disc. Check the operation of the brake before riding the motorcycle.
Rear brake shoes - XL600V-H to L (1987 to 1990) models
23. Remove the rear wheel (see Section 14).
24. Lift the brake plate out of the drum In the wheel hub (see illustration).
2.24. Drum brake components - XL600V-H to L (1987 to 1990) models: 1. Brake arm; 2. Indicator plate; 3. Grease seal; 4. Brake plate; 5. Grease seal; 6. Thrust plate; 7. Brake shoes; 8. Actuating cam
25. Note which way round the shoes fit and how they locate against the actuating cam and the spindle they pivot on. Grasp each shoe and 'fold' them up towards each other-when they are almost vertical the springs win relax and the shoes can be lifted of the cam and the spindle. Remove the springs.
26. Check the brake shoe linings for wear, damage and signs of contamination from road dirt or water. If the linings are visibly defective, renew the shoes. Measure the thickness of the lining material (just the lining material, not the metal backing) and renew the shoes If the linings have worn down to or below the minimum thickness (see Specifications) at any point.
27. Check the ends of the shoes where they contact the brake cam and pivot posts and renew the shoes if there are signs of wear. Check the lugs on the shoes where the springs locate. Also check that the springs am not stretched and that their ends are not deformed.
28. Clean all old grease from the flats of the operating cam and around the spindle, then apply a smear of fresh copper grease to these areas ensuring that none gets on the lining material.
29. Fit the springs into the shoes and hold Ihe shoes 'folded' together so that the springsafe under a slight tension and will not drop out. Pull the ends of the shoes apart slightly and locate them against the actuating cam and the spindle, then fold the shoes flat onto the brake plate so that the springs become tensioned and effectively pull the ends of the shoes against the cam and spindle. Operate the cam and check that the shoes pivot correctly.
30. Fit the brake plate assembly into the drum in the rear wheel hub. Install the wheel (see Section 14).
Rear brake pads - XL600V-M to X (1991 to 1999) models, XL650V models and XRV750 models
31. To allow for the increased friction material thickness of new pads, push the brake caliper against the disc so that the piston is forced back into the caliper (see illustration). It may be necessary to remove the master cylinder reservoir cover and diaphragm and siphon out some fluid. If the pistons are difficult to push back, attach a length of clear hose to the bleed valve and place the open end in a suitable container, then open the valve and try again. Take great care not to draw any air into the system. If in doubt, bleed the brakes afterwards (see Section 10).
2.31. Push the caliper against the disc to force the piston in
32. Unscrew the pad retaining pm plug, then slacken the pad retaining pin (see Illustrations). On XL600V models unscrew the bolt securing the brake hose clamp to the caliper bracket (see illustration).
2.32a. Unscrew the plug...
2.32b ...then slacken the retaining pin (arrowed)
2.32c. Remove the brake hose clamp bolt
33. Unscrew the caliper rear mounting bolt/slider pin (see illustration). Pivot the back of the caliper up off the disc then unscrew the pad retaining pin and remove the pads, noting how they fit (see illustration). Note the pad spring in the top of caliper and the pad guide on the caliper bracket and remove them If required for cleaning or replacement, noting how they fit.
2.33a. Unscrew the bolt (arrowed)...
2.33b ...then pivot the caliper up, withdraw the retaining pin and remove the pads
34. Refer to Steps 6, 7 and 8 above.
35. Install the pads so that the friction material of each pad will face the disc and insert the pad pin, tightening it finger tight (see illustration). Pivot the caliper down onto the disc while keeping the pads held in position, locating the leading edges correctly against the guide on the bracket (see Illustration). Apply a suitable non-permanent thread locking compound to the rear mounting bolt/slider pin and tighten it securely (see illustration). Now tighten the pad pin securely. Install the pad pin plug - It is advisable to apply some copper or silicone grease to its threads (see Illustration 2.32a).
2.35a. Locate the pads and insert the retaining pin
2.35b. Make sure the pads locate correctly (arrow)
2.35c. Install the bolt and tighten it securely
36. Top up the master cylinder reservoir if necessary (see Daily (pre-ride) checks).
37. Operate the brake lever several times to bring the pads into contact with the disc. Check the operation of the brake before riding the motorcycle.