Installation

1. Positionthecaliperoverthedisctakingcarenottodamagethewheel.

2. Tightenthecaliperboltsto40Nm.

3. Refitthebrake padsasdescribedonpage15.11.

4. Connectthebrake hosetothecaliperincorporatingnewsealingwashersoneachsideoftheunion.

5. Tightenthebrakehoseunionboltto25Nm.

1. Fitnewfluidsealstothepistonboresinthecaliper.

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1. Caliperbore

2. Fluidseal

6. Fillthemastercylinderwithnew,DOT4brakefluidfromasealedcontainer.

7. Bleedthefrontbrakelineasdescribedonpage

15.9.

6. Checktheoperationofthefrontbrake.Rectifyasnecessary.

15.14 ServiceManual-RocketIll Removal

FrontDiscs

1. Removethefrontwheelasdescribedonpage

16.6.

Wear

FrontDiscThickness
Standard	5.0mm
Servicelimit	4.0mm

1. Replaceanybrakediscifwornbeyondtheservicelimitorexceedsthediscrun-outlimit.

DiscRun-out
Standard	0.1mm
Servicelimit	0.3mm

Measurediscrunoutusinganaccuratedialgaugemountedonasuriaceplate.

""'

1.Disc

2.DialGauge

2. Supportthewheelonblocksasillustrated.

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1. Wheel

2. Supportblock

3. Removeanddiscardthediscsecuringbolts.

4. Detachthedisc.

5. Repeat operations2, 3and4toremovethediscontheoppositeside.

ServiceManual-RocketIll

15.15

Installation

1. Locatethefirstdisconthecorrectsideofthewheel(offsetofdiscoutwards)asnotedduringremoval.

2. Fitnewdiscboltsandtightento22Nm.

3. Fittheremainingdiscinthesameway.

4. Refitthewheelasdescribedonpage16.7.

5. Checktheoperationofthefrontbrake.Rectifyasnecessary.

FrontBrakeMasterCylinder

Removal

1. Removetheseatanddisconnectthebatterynegative{black)leadfirst.

2. Todrainthefluidfromthemastercylinder,attachatubetotherighthandcaliperbleednipple,slackenthenippleandoperatethebrakeleveruntilallfluidhasbeenexpelledintoasuitablecontainer.

3. Removetherighthand switchcubeasdescribedon page11.116.

4. Disconnectthethrottlecablesasdescribedonpage11.116.

5. Notethesettingofthebrakeleveradjustertoensureitisreturnedtothesamepositionwhentheoverhauloperationiscomplete.

1.Lever

2. Adjuster wheel

3. Triangularmark

6. Disconnectthebrakehoseandbrakelightswitchconnectionstothemastercylinder.

7. Releasetheclampscrewsfromthehandlebartoremovethemastercylinder.

^15.16 ServiceManual- RocketIll

Disassembly

1.Removethepivotlocknutandboltsecuringthebrakelevertothemastercylinder.Removethelever.

2. Detachthedustcoverfromtheleverendofthecylinder.

"'"

1.Dustcover

3. Removethecirclipfrombeneaththedustcover.

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1.Circlip

3. Removethepistonsetfromthemastercylinderborenotingtherelativepositionofthesealsandpistoncomponents.

1.PistonSet

Inspection

1. Checkthefollowingfor wear,damage,cracksordeterioration:

"'"'

1. Cylinderbore(1)

2. Dustcover(2)

3. Spring(3)

4. Piston(4)

5. PivotBolt(5)Note:

   • Alwaysrenewthepistonandsealsetifthecylinderisdismantled.

• ServiceManual-RocketIll

15.17

2. Checkthatthereliefandsupplyportsonthecylinderarenotblocked.

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1.Ports

Assembly

1. Lubricatethepistonandcylinderwithnew,cleanbrakefluid.

2. Fitthenewpistonsetintothemastercylinderandretainwithanewcirclip.

1. Piston

2. Seal(incorrectorientation)

3. Refitthemastercylinderdustcover.