1.Diaphragm

7. Releasethebleednipple.

1. BleedNipple

2. Spanner

3. BleedTube

4. Container

• ServiceManual-RocketIll

15.9

16. Whenbothcalipershavebeenbled,ensurethebrakeleveroperationhasafirmresistivefeeltoit,doesnotfeelspongyandthatthelevercannotbepulleddirectlybacktothehandlebar.Takeremedialaction asnecessary.

17. Refitthediaphragmandreservoircover.Tightenthescrewsto2Nm.

Note:

• Duringbleeding,donotallowthefluidleveltofallbelowthelowerlevelmarkinthe reservoir.Ifthefluidlevelisallowedtofallbelowthismark,airmayenterthesystemandthesequenceofbleedingmustberepeated.

10. Slowlypullthebrakelevertothehandlebarand,holdingtheleverfullyin,closethebleednipple.Repeatsteps9and10untilnomoreair appearsinthebleedtube,maintainingthebrakefluidlevelbetweentheupperandlowerreservoirlevelswhilstbleedingisbeingcarriedout.

11. Whenallairhasbeenexpelledfromthesystem,holdthelever inandclosethebleednipple.Tightenthenippleto7Nm.

12. Fillthe reservoirtotheupperlevelwithnewDOT4fluid.

18. Resetthebrakeleveradjustertotheoriginalsetting.

19. Checktheoperationofthefrontbrake.Rectifyasnecessary.

13. Removethebleedtube.

14. Replacethebleednipplecap.

15. Repeattheprocedurefortheleft-handcaliper.

15.10 ServiceManual-RocketIll

FrontBrakePads

Removal

4. Removebothbrakepadsandinspectfordamageandwearbeyondtheservicelimit.

Note:

Brakepadremoval

• Completetheassemblyofthebrakepadstoonecaliper(seeassemblyfordetails)beforeremovingthepadsfromtheothercaliper.

"'"

1. RetainingPin

2. Anti-rattleSpring

3. BrakePads

1. Removethebrake padretainingpinafterremovinganddiscardingitssplitpin.Inspecttheretainingpinfordamage.

2. Remove theanti-rattlespringandinspectthespringfordamage.

Installation

3. Carefullypushthebrakepadsaparttoforcethecaliperpistonsbackandallowwithdrawalofthepads.

_- ServiceManual-RocketIll

15.11

1. Fitnewbrakepadsasanaxlesetor,ifallthepadsareinaserviceablecondition,cleanthepadgroovesbeforerefitting allpadsintheiroriginalpositions.

6. CheckthefrontbrakefluidlevelandtopupasrequiredwithnewDOT4fluid.

7. Checktheoperationofthefrontbrake.Rectifyasnecessary.

2. Lubricatethepadretainingpinsusingaminimumamountofproprietaryhightemperature'Copperslip'typegrease.

3. Fittheanti-rattlespringoverthepadsandpushdowninthecentretoallowthepadretainingpintoslide acrossthetopofthespring.

4. Tightenthepadretainingpinto18Nm,andsecurewithanewsplitpin.

5. Pumpthebrakelevertocorrectlypositionthecaliperpistons.

15.12 ServiceManual-RocketIll

FrontBrakeCaliper

Removal

Disassembly

1. Disconnectthebrakehoseatthecaliperandplacethefreeendofthehoseinasuitablecontainertocollect anydisplacedbrakefluid.

2. Removethebrakepadsasdescribedonpage

15.11.

3. Removethetwocaliperbolts.

4. Manoeuvrethecaliperclearofthedisc,takingcare nottodamagethewheel.

1. .Caliper

2. Wheel

1.Coverthecaliperopeningwithaclean,heavyclothand,usingeithercompressedairblownintothebrakehoseconnectionpoint,orbyreconnectingthemastercylinderandpumpingthebrakelever,removeeachofthepistons,oneatatime.

1. Caliper

2. Fluidsupply

ServiceManual-RocketIll

15.13

Inspection

1. Checkthepistonsandcaliperboresforcorrosion,scoringanddamage.Renewasnecessary.

2. Inspectthebrakepadsfordamageandwearbeyondtheservicelimit.Renewasnecessary.

Assembly

Ensurethattheboresdonotbecomescratchedduringpistonremovalandassembly.Ensurethatthepistonsremainsquaretotheirboresduringfitment,asincorrectfitmentcanleadtosealandboredamage.Adangerousridingconditionleadingtolossofcontrolandanaccidentcouldresultfromdamagedsealsand/orbores.

2. Applybrakefluidtotheoutsideofthecaliperpistonsandfluidseals.

3. Carefullypushthepistonsfullyandsquarelyintothecaliperboresbyhand.