Front brake system — design description 1. GTZ piston*; 2. Diaphragm; 3. Brake hose; 4. Brake pads; 5. Set of caliper pistons; A. Bolt of the GTZ mounting clamp; B. Brake hose fitting; C. Caliper mounting bolt; D. Air bleed fitting; E. Pad mounting bolt; F. Plug *GTC – master brake...
Front Brake System — Precautions Warning! The brake system is filled with DOT4 glycol-based brake fluid. Do not use (or mix) brake fluid of a different specification (based on silicone or petroleum products) when replacing, as this can cause serious damage to the brake system. Do...
Replacing front brake pads Remove the plug (1) and loosen the pad bolt (2). Remove the caliper mounting bolts (3). Remove the pad and pad mounting bolts (4). Attention! Do not press the brake lever with the pads removed. Replace the pads as a set, otherwise braking...
Replacing brake fluid in the front brakes Place the motorcycle on a flat surface with the handlebars straight. Remove the master cylinder cap and diaphragm (GTZ). Pump out as much of the old brake fluid as possible from the reservoir. Fill the reservoir with new brake fluid. Brake fluid...
Removing and disassembling the front brake caliper Disconnect the hose from the brake caliper (unscrew the fitting (1)), let the liquid drain into a container. Remove the caliper by unscrewing the mounting bolts (2). Warning! Never reuse brake fluid that was left over from a previous change or that...
Defective front brake caliper Stopping support Inspect the piston guide walls on the brake calipers for scratches, dents or other damage. If damage is detected, replace the brake caliper. Brake caliper pistons Inspect the brake caliper pistons for scratches or other damage. If...
Assembly and installation of the front brake caliper Assemble and install the brake caliper in the reverse order of removal and disassembly. Pay attention to the following nuances: Wash the bores in the calipers, as well as the pistons, in appropriate brake fluid. Thoroughly wash the O-ring grooves...
Defective front brake disc Check the brake disc for cracks or damage, then measure the thickness of the disc with a micrometer. If damage or increased wear is detected (disc thickness below permissible limit) replace the disk. 09900-20205: Micrometer (0-25 mm) Disc thickness....
Master brake cylinder (front) — dismantling and disassembly Remove the front brake lever protection. Remove the front brake lever. Note. Don't lose the spring (1). Place a rag under the brake hose fitting. Remove the fitting and disconnect the brake hose. Warning! Immediately wipe off brake fluid that gets...
Defective master cylinder (front) Master brake cylinder Check the surface of the piston guide in the caliper for scratches or other damage. If damage is detected, replace the caliper. Piston and rubber parts Check the surface of the piston, cuff (primary/secondary), boot for wear,...
Master brake cylinder (front) — assembly and installation Assemble and install the brake master cylinder in the reverse order of removal and disassembly. Pay attention to the following nuances: Attention! Flush the brake caliper components with new brake fluid before reassembling. Do not wipe off brake...
Rear brake system — design description 1. Caliper body; 2. Mounting the caliper; 3. Piston; 4. Gasket; 5. Brake pads; 6. Tank hose; 7. Brake hose; 8. Piston with cuffs; A. Bolt securing the pads; B. Air bleeder fitting; C. Brake hose fitting; D. Brake master cylinder mounting bolt; E....
Rear Brake System — Precautions Warning The brake system is filled with DOT4 glycol-based brake fluid. Do not use (or mix) brake fluid of a different specification (based on silicone or petroleum products) when replacing, as this can cause serious damage to the brake system. Do...
Replacing rear brake pads Remove the rear wheel ( section 5-24 ). Remove the caliper protection (1). Remove the pad mounting bolts (2). Remove the pads (3) with gaskets. Attention! Do not press the brake pedal while the pads are removed. Replace the pads as a set to avoid...
Replacing brake fluid in rear brakes Remove the right cover ( section 5-3 ). Remove the reservoir cap. Replace the brake fluid ( section 5-40 ). Brake fluid: DOT 4 Attention! Bleed the brake system ( section 2-17 ).
Rear brake caliper — removal and disassembly Remove the rear wheel ( section 5-24 ). Remove the caliper protection ( section 5-48 ). Remove the pads ( section 5-48 ). Disconnect the brake hose from the caliper (unscrew the fitting), drain the brake fluid into a suitable container. Remove the...
Rear brake caliper — assembly and installation Assemble and install the brake caliper in the reverse order of removal and disassembly. Pay attention to the following nuances: Wash the bores in the calipers, as well as the pistons, in appropriate brake fluid. Thoroughly wash the O-ring grooves...
Master brake cylinder (rear) — dismantling and disassembly Remove the right cover ( section 5-3 ). Place a rag under the brake hose fitting. Remove the fitting and disconnect the brake hose, drain the brake fluid into a suitable container. Attention! Immediately wipe off any brake fluid that gets on your...
Master brake cylinder (rear) — assembly and installation Assemble and install the brake master cylinder in the reverse order of removal and disassembly. Pay attention to the following nuances: Attention! Flush the brake caliper components with new brake fluid before reassembling. Do not wipe off brake...