Ingsolventsuchasgasoline,kerosineortheothers.

*Replacethepistonsealsanddustsealswithnewoneswhenreassembly.Applythebrakefluidtobothsealswheninstallingthem.

PISTONSEAL

•Installthepistonsealsasshownintherightillustration.

0-ring

•Installthe0-ringsandputcaliperhalvestogether.

•Tighteneachbolttothespecifiedtorque.

(!)FrontbrakecaliperhousingboltG):

21N·m(2.1kgf·m,15.1lb-ft)Frontbrakecalipermountingbolt~:

25N·m(2.5kgf·m,18.1lb-ft)Frontbrakehoseunionbolt@:

_{23N·m(2.3kgf·m,16.5lb-ft)}

NOTE:

Beforeremountingthecaliper.pushthepistonallthewayintothecaliper.

IACAUTIONI

Bleedairfromthesystemafterreassemblingthecaliper.(c::::t2-25)

BRAKEDISCINSPECTION

_{Visuallycheckthebrakediscfordamageorcracks.}

_{Measurethethicknesswithamicrometer.}⁽

Replacethediscifthethicknessislessthantheservicelimitorifdamageisfound.

~Frontdiscthickness:ServiceLimit:4.5mm(0.18in)

i-r'OOL!09900-20205:Micrometer(0-25mm)

•Removethebrakecalipers.(c::::T6-56)Measuretherunoutwithadialgauge.

_{Replacethedisciftherunoutexceedstheservicelimit.}

^{mFrontdiscrunout:ServiceLimit:0.30mm(0.012in)}

Irk!09900-20606:Dialgauge(1/100mm)

09900-20701:Magneticstand

*Brakediscremoval(c::::;r6-8)

*Brakediscinstallation(C:::?6-11)

MASTERCYLINDERREMOVALANDDISASSEMBLY

•Disconnectthefrontbrakelightswitchleadwires.

•Placearagunderneaththeunionboltonthemastercylindertocatchanyspiltbrakefluid.Removetheunionboltanddiscon•nectthebrakehose.

^...._IACAUTIONI

Immediatelyandcompletelywipeoffanybrakefluidcon•tactinganypartofthemotorcycle.Thefluidreactschemi•callywithpaint,plasticsandrubbermaterials,etc.andwilldamagethemseverely.

•Removethemastercylinderbyremovingthemastercylinderbolts.

•Removethereservoircap".D,insulator~anddiaphragm@.

•Removethebrakelever@andbrakeswitch@.

•Pulloutthedustboot(Dandremovethecirclip(2\

1£8t109900-06108:Snapringpliers.

•Removethepiston/secondarycup,primarycupandreturnspring.

®Secondarycup

@)Piston

@Primarycup

'IDReturnspring

•Removethecirclip({),connector@and0-ring:ID.

MASTERCYLINDERINSPECTION

Inspectthemastercylinderboreforanyscratchesorotherdam•

age.

Inspectthepistonsurfaceforanyscratchesorotherdamage.Inspecttheprimarycup,secondarycupanddustsealforwearordamage.

MASTERCYLINDERREASSEMBLYANDREMOUNTING

Reassemblethemastercylinderinthereverseorderofremovalanddisassembly.Payattentiontothefollowingpoints:

1^ACAUTIONI

*Washthemastercylindercomponentswithfreshbrakefluidbeforereassembly.Neverusecleaningsolventorgasolinetowashthem.

*Donotwipethecomponentswitharag.

*Applybrakefluidtothecylinderboreandallthecom•

a

ponenttobeinsertedintothebore.SpecificationandClassification:DOT4

-

-

•Whenremountingthebrakemastercylinderontothehandle•

bar,alignthemastercylinderholder'smatingsurfacewithpunchedmark<6onthehandlebarandtightentheupperclampboltfirstasshown.

~Frontbrakemastercylindermountingbolt:10N·m

_{(1.0kgf·m,7.0lb-ft)}

Upperclampbolt

•Tightentheunionbolt.(Brakehoserouting:c:::::T'8-20)

~Brakehoseunionbolt:23N·m(2.3kgf·m,16.5lb-ft)

•Bleedairfromthebrakesystem.(c::?2-24)

INSPECTIONAFTERREASSEMBLY

•Frontbrake:c:::::T'2-22

REARBRAKE

_CONSTRUCTION

ITEM

_®

@

N·m	kgf·m	lb-ft
8	0.8	6.0	'fBrakepedal
23	2.3	16.5	?Piston/cups :3.JReservoirta

_©252.518.1

'.~^101.07.0

_~^181.813.0

_,4Brakehose

•2Pad

_{'~·Innershim}

^{•JOutershim}

_'~Piston

et

nkhose

A,Caliperairbleedervalve

~Brakehoseunionbolt

_{~Rearbrakecalipermountingbott}

QRearbrakemastercylindermountingbolt

_{i;-Rearbrakemastercylinderrodlocknut}

^{(£)303.021.5}

1gBrakepadcover

ERearbrakecaliperhousingbolt

AWARNING

*Thisbrakesystemisfilledwithanethyleneglycol-basedDOT4brakefluid.Donotuseormixdifferenttypesoffluidsuchassilicone-basedorpetroleum-based.

..Donotuseanybrakefluidtakenfromold,usedorunsealedcontainers.Neverreusebrakefluidleftoverfromthelastservicingorstoredforlongperiods.

*Whenstoringthebrakefluid,sealthecontainercompletelyandkeepawayfromchildren.

*Whenreplenishingbrakefluid,takecarenottogetdustintofluid.

*Whenwashingbrakecomponents,usefreshbrakefluid.Neverusecleaningsolvent.

•Acontaminatedbrakediscorbrakepadreducesbrakingperformance.Discardcontaminatedpadsandcleanthediscwithhighqualitybrakecleanerorneutraldetergent.

IACAUTIONI

Handlebrakefluidwithcare:thefluidreactschemicallywithpaint,plastics,rubbermaterialsetc.-

BRAKEPADREPLACEMENT

•Removethebrakepadcover.

•RemovetheclipG).

•Removethebrakepadsalongwiththeshimsbyremovingthebrakepadmountingpins~andsprings@.

IACAUTIONI

*Donotoperatethebrakepedalwhiledismountingthepads.

*Replacethebrakepadsasaset,otherwisebraking

._performancewillbeadverselyaffected.

•Installthenewbrakepadsandshims.

IACAUTIONI

Besuretoinstalltheshimsproperlyasshownintheillustration.

NOTE:

Afterrep!acingthebrakepads,pumpthebrakepedalfewtimestooperatethebrakecorrectlyandthencheckthebrakefluidlevel.

BRAKEFLUIDREPLACEMENT

•Removetheframecover.(c:::J6-6)

•Removethebrakefluidreservoircap.

•Replacethebrakefluidinthesamemannerasthefrontbrake.(c:::::r6-55)

~SpecificationandClassification:DOT4

lACAUTIONI

IBleedairfromthebrakesystem.(c::T2-25)

CALIPERREMOVALANDDISASSEMBLY

•RemovetheunionboltG)andcatchthebrakefluidinasuitablereceptacle.

'.ACAUTIONI

Neverreusethebrakefluidleftoverfrompreviousser•

vicingandstoredforlongperiods.

AWARNING

Brakefluid,ifitleaks,willinterferewithsaferunninganddiscolorpaintedsurfaces.Checkthebrakehoseandhosejointsforcracksandfluidleakage.

•Removethebrakecalipermountingbolts~andtorquelinkbolt@.

NOTE:

Slightlyloosenthecaliperhousingbolts@tofacilitatelaterdis•

_{assemblybeforeremovingthecalipermountingbolts.}

•Removethebrakepads.(c:::?6-63)

•Removethecaliperhousingbolts@.

•Separatethecaliperhalves.

•Removethe0-ring@.

_IACAUTIONI

^{IReplacethe0-ringwithanewone.}

-

•Placearagoverthepistontopreventitfrompoppingoutandthenforceoutthepistonsusingcompressedair.

IACAUTIONI

Donotusehighpressureairtopreventpistondamage.

•Removethedustsealsandpistonseals.

,ACAUTIONI

Donotreusethedustsealsandpistonsealstopreventfluidleakage.

-

_{CALIPERINSPECTION}

CALIPERINSPECTION:c::::r6-57

BRAKEDISCINSPECTION:c::::r6-58

~ServiceLimit

Reardiscthickness:4.5mm(0.18in)Reardiscrunout:0.30mm(0.012in)

CALIPERREASSEMBLYANDREMOUNTINGReassembleandremountthecaliperinthereverseorderofre•movalanddisassembly.Payattentiontothefollowingpoints:

IACAUTIONI

*Washthecalipercomponentswithfreshbrakefluidbeforereassembly.Neverusecleaningsolventorgaso•linetowashthem.

*Applybrakefluidtothecaliperboreandpistontobeinsertedintothebore.

~SpecificationandClassification:DOT4

PISTONSEAL

•Installthepistonsealsasshownintherightillustration.

•Tighteneachbolttothespecifiedtorque.

(!)Brakehoseunionbolt'I::23N·m(2.3kgf·m,16.5lb-ft)Rearbrakecalipermountingbolt(?'):25N·m

(2.5kgf·m,18.1lb-ft)Reartorquelinknut@:34N·m(3.4kgf·m,24.6lb-ft)

Rearbrakecaliperhousingbolt@:30N·m

_{(3.0kgf·m,21.5lb-ft)}

~

Dustseal

_ll.o~

Fl1.1id

_®®·~

[ACAUTIONI

_{Bleedairfromthesystemafterreassemblingthecaliper.}

(c::::r2-25)

MASTERCYLINDERREMOVALANDDISASSEMBLY

•Removetheframecover.(c:::::t6-6)

•Removethebrakefluidreservoirtankmountingbolt(j).

•Placearagunderneaththeunionboltonthemastercylindertocatchspilleddropsofbrakefluid.Removetheunionbolt~anddisconnectthebrakehose.

•Loosenthelocknut@.

•Removethemountingbolts®·

IACAUTIONI

Immediatelyandcompletelywipeoffanybrakefluidcon•tactinganypartsofthemotorcycle.Thefluidreactschemicallywithpaint,plasticandrubbermaterials,etc.

_{andwilldamagethemseverely.}

•Disconnectthehose.

•Removethemastercylinderbyturningthemastercylinderrod

'~'.

•Removethereservoircapanddiaphragm.

•Removetheconnectorbyremovingthescrew.

•Removethe0-ring®·

IACAUTIONI

IReplacethe0-ringwithanewone.

•Pulloutthedustsealthenremovethecirclipwiththespecialtool.

tRmti09900-06108:Snapringpliers

•Removethepushrod,piston/primarycupandspring.

....

-

-

-

-

MASTERCYLINDERINSPECTION

CYLINDER,PISTONANDCUPSET

Inspectthecylinderborewallforanyscratchesorotherdamage.Inspectthecupsetandeachrubberpartfordamage.

MASTERCYLINDERREASSEMBLYANDREMOUNTING

Reassembleandremountthemastercylinderinthereverseor•derofremovalanddisassembly.Payattentiontothefollowingpoints:

ACAUTIONI

*Washthemastercylindercomponentswithfreshbrake

- fluidbeforereassembly.Neverusecleaningsolventorgasolinetowashthem.

•Applybrakefluidtothecylinderboreandallthecom•

ponenttobeinsertedintothebore.

~SpecificationandClassification:DOT4

•Tighteneachbolttothespecifiedtorque.(Brakehoserouting:c:::::?8-21)

(!)BrakehoseunionboltG):23N·m(2.3kgf·m,16.5lb-ft)Rearmastercylindermountingbolt~:

10N·m(1.0kgf·m,7.0lb-ft)Rearmastercylinderrodlocknut@:

18N·m(1.8kgf·m,13.0lb-ft)

•Bleedairfromthebrakesystem.(c:::::?2-25)

INSPECTIONAFTERREASSEMBLYRearbrake:c:::::?2-23

@d