Inside Circlip Pliers: 57001-143

12-8 BRAKES

Brake Lever and Brake Pedal

Brake Lever Position Adjustment

The adjuster has 4 positions so that the brake lever posi­tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align

the number with the Arrow mark [B] on the lever holder. ○The distance from the grip to the released lever is mini­mum at Number 4 and maximum at number 1.

Brake Pedal Position Inspection

• With the brake pedal [A] in the correct position, inspect the brake pedal position [B] as shown.

Footpeg [C]

Pedal Position Standard: 30 ~ 40 mm (1.2 -1.6 in.) below

footpeg (from Top of the footpeg to Top of the brake Pedal)

• If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTE

О Usually it is not necessary to adjust the pedal position, but always adjust it when push rod locknut has been loosened.

• 

  Loosen the locknut [A], and turn the push rod [B] in or out to adjust the brake pedal position.

• Tighten the locknut.

• After adjusting brake pedal position, check the rear brake light switch timing, and adjust them if necessary (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter).

Brake Pedal and Shaft Removal

• Remove the front right footpeg bolt [A].

• Remove the brake pedal bolt [B], and remove the brake pedal.

• Remove the cotter pin [C], and pull out the pin [D] to sepa­rate the brake pedal shaft and master cylinder brake rod.

BRAKES 12-9

Brake Lever and Brake Pedal

Remove brake light switch spring [A] and shaft spring [B].

Brake Pedal and Shaft Installation

• Install the brake shaft and connect the brake rod and brake shaft with pin.

• Install the new cotter pin and bend the end of it surely.

• Connect the rear brake light switch spring.

• Install the brake pedal aligning the punch marks [A] on the brake lever and brake shaft.

12-10 BRAKES

Caliper

Front Caliper Removal

• Drain the brake fluid.

• Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

• Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

• Unscrew the banjo bolt and remove the brake hose [D] from the caliper.

NOTE

○If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston us­ing the following steps before disconnecting the brake hose from the caliper.

○Remove the pads (see Pad Removal).

CAUTION

Immediately wash away any brake fluid that spills.

○Pump the brake lever to remove the caliper piston.

Front Caliper Installation

• Install the caliper and brake hose lower end. OReplace the washers that are on each side of hose fitting

with new ones.

• Tighten the caliper mounting bolts and banjo bolt.

Torque -CaliperMounting Bolts: 34N-m (3.5kgf-m, 25ft-lb) Brake Hose Banjo Bolt: 34 N-m (3.5 kgf-m, 25 ft-lb)

• Check the fluid level in the brake reservoir, and bleed the brake line (see Bleeding the Brake Line).

• Check the brake for good braking power, no brake drag, and no fluid leakage.

Rear Caliper Removal

• Drain the brake fluid.

• Loosen the banjo bolt [A] at the caliper side, and tighten it loosely.

• Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

• Unscrew the banjo bolt and remove the brake hose [D] from the caliper.

NOTE

О If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston us­ing the following steps before disconnecting the brake hose from the caliper.

О Remove the pad (see Pad Removal).

О Pump the brake lever to remove the caliper piston.