Front brake construction 1. Dust boot; 2. Piston set; 3. Cap; 4. Diaphrapm; 5. Master cylinder; 6. Piston seal; 7. Dust seal; 8. Brake caliper piston; 9. Brake pad; 10. Brake pad spring; A. Master cylinder mounting bolt; B. Brake caliper mounting bolt; C. Brake caliper air...
Brake pad replacement of front brake Loosen the pad mounting pins 1. Remove the brake caliper by removing the caliper mounting bolts 2. Remove the pad mounting pins 1, brake pads. Caution: Do not operate the brake lever with the pads removed. Replace the brake pads as a set, otherwise...
Brake fluid replacement of front brake Place the motorcycle on a level surface and keep the handlebars straight. Remove the brake fluid reservoir cap 1 and diaphragm. Drain the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Connect a clear hose to the...
Front caliper removal Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. Note: Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. Remove the brake pads. ( 9-52 )...
Front caliper disassembly Remove the pad spring 1. Remove the caliper air bleeder valve 2. Separate the caliper halves by removing the caliper housing bolts 3 with the special tools. 09930-11920: Torx bit JT40H 09930-11940: Bit holder Remove the O-ring 4. Caution: Replace...
Front caliper inspection Brake caliper Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace it with a new one. Brake caliper piston Inspect the brake caliper piston surface for any scratches or other damage. If any...
Front caliper reassembly Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. Specification and...
Front caliper installation Install the caliper in the reverse order of removal. Pay attention to the following points: Install the brake pads and brake caliper. ( 9-53 ) To the specified torque. Brake hose union bolt: 23 Nm (2.3 kgf·m, 16.5 lb·ft) Caution: The seal washers...
Front brake disc inspection Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. Front disc thickness: Service Limit: 4.5 mm (0.18 in) 09900-20205:...
Front master cylinder removal and disassembly Drain the brake fluid. ( 9-53 ) Disconnect the front brake light switch lead wire coupler 1. Place a rag underneath the union bolt 2 on the master cylinder to catch any split brake fluid. Remove the union bolt and disconnect the brake hose. Caution:...
Front master cylinder inspection Master cylinder Inspect the master cylinder bore for any scratches or damage. If any defects are found, replace the master cylinder with a new one. Piston and rubber parts Inspect the piston surface for any scratches or other damage. Inspect the...
Front master cylinder reassembly Reassemble the master cylinder in the reverse order of disassembly. Pay special attention to the following points: Caution: Wash the master cylinder components with new brake fluid before reassembly. Do not wipe the brake fluid off after washing the...
Front master cylinder installation Install the master cylinder in the reverse order of removal. Pay attention to the following points: When remounting the master cylinder onto the handlebars, align the master cylinder holder's mating surface with the punch mark ® on the handlebars...
Rear brake construction 1. Piston/Cup set; 2.Reservoir hose; 3. Brake hose; 4. Brake pad; 5. Piston; 6.Piston seal; 7. Dust seal; 8. Brake pad spring; A. Caliper air bleeder valve; B. Brake hose union bolt; C. Brake master cylinder rod lock nut ITEM Nm kgf·m lb·ft A 7.5...
Brake pad replacement of rear brake Remove the brake caliper by removing the brake caliper mounting bolts. Remove the cotter pin 1. Remove the pad mounting pin 2. Remove the brake pads 3. Caution: Do not operate the brake pedal with the pads removed. Replace the brake pads as a set,...
Brake fluid replacement of rear brake Remove the right frame head cover and right radiator cover. ( 9-6 ) Place the motorcycle on a level surface. Remove the brake fluid reservoir cap 1 and diaphragm. Drain the old brake fluid as much as possible. Fill the reservoir with new brake...
Caliper removal of rear brake Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. Note: Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. Remove the brake caliper. ( 9-63...
Caliper disassembly of rear brake Remove the brake pads. ( 9-63 ) Remove the springs 1 and brake caliper holder 2. Remove the caliper air bleeder valves 3. Remove the rubber boots 4. Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the...
Caliper inspection of rear brake Brake caliper Inspect each brake caliper cylinder wall for nicks, scratches or other damage. If any defects are found, replace the brake caliper with a new one. Brake caliper pistons Inspect the brake caliper pistons for any scratches or other...
Caliper reassembly of rear brake Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. Specification and...
Caliper installation of rear brake Install the caliper in the reverse order of removal. Pay attention to the following points: Install the brake pads and brake caliper. ( 9-64 ) Tighten brake hose union bolt to the specified torque. (Rear brake hose routing: 11-40 ) Brake hose union...
Master cylinder removal of rear brake Remove the right frame head cover and right radiator cover. ( 9-6 ) Remove the exhaust pipe and muffler. ( 7-8 ) Drain the brake fluid. ( 9-64 ) Note: Temporarily tighten the reservoir cap. Remove the brake fluid reservoir mounting bolt. Remove the...
Master cylinder disassembly of rear brake Remove the reservoir cap 1 and diaphragm 2. Remove the snap ring 3, connector 4 and O-ring 5. 09900-06108: Snap ring pliers Caution: Replace the removed O-ring 5 with a new one. Pull out the dust boot 6, then remove the snap ring 7. 09900-06108:...
Master cylinder reassembly of rear brake Reassemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: Caution: Clean the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them....
Master cylinder installation of rear brake Install the master cylinder in the reverse order of removal. Pay attention to the following points: Temporarily tighten the master cylinder mounting bolts. Tighten the lock nut 1 and brake hose union bolt 2 to the specified torque. (Brake hose...
Front brake hose routing Front brake hose routing 1. Stopper; 2. Brake master cylinder; 3. Throttle cable; 4. Cable guide; 5. Hose guide; 6. Brake hose; 7. Clamp; 8. Bolt; 9. Brake caliper (R); 10. Brake caliper (L); *1. Tighten the brake hose union bolt to the specified...
Rear brake hose routing Rear brake hose routing 1. Stopper; 2. Reservoir; 3. Brake cylinder; 4. Brake hose; 5. Brake caliper; 6. Clamp; 7. Face the tip of clamp to backward; 8. Face the tip of clamp to upper; 9. Starter motor lead wire; 10. Insert the reservoir hose fully...