BRAKES 12-13

Calipers

Caliper• Piston and Cylinder Damage

Visually inspect the piston [E] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty.

Fluid Seal [A]

Dust Seal [B]

Rubber Boot [C]

Front Caliper [J]

Rear Caliper [K]

Caliper Holder Shaft Wear

The caliper body must slide smoothly on the caliper holder shaft [F]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature• .

Check to see that the caliper holder shaft are not badly worn or stepped, and that the rubber friction boots [D] are not damaged.

If the rubber friction boot is damaged, replace the rubber friction boot. To replace the friction boot, remove the pads and the caliper bracket.

If the caliper holder shaft is damage, replace the caliper bracket.

12-14 BRAKES

Brake Pads

Front• Brake Pad Removal

•Remove the caliper from the disc.

Draw out the holder shaft pin [A], and take off the holder

•shaft [B].

•Remove the pad [C] on the piston side.

Push the holder [D] towards the piston, and remove the pad of the other side [E] from the holder shaft [F].

Front• Brake Pad Installation

•Push the caliper pistons in by hand as far as they will go.

•Install the anti-rattle spring in its correct position.

Install the pad on the piston side first, then install the other

•pad on the holder.

Install the caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.

Rear• Brake Pad Removal

•Remove the caliper with the hose installed.

Draw out the holder shaft pin [A], and take off the holder

•shaft [B].

•Remove the pad [C] on the piston side.

Push the holder [D] towards the piston, and remove the pad of the other side [E] from the holder shaft [F].

Rear• Brake Pad Installation

•Push the caliper piston in by hand as far as it will go.

•Install the anti-rattle spring in its correct position.

Install the pad on the piston side first, then install the other

•pad on the holder.

Install the caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done.

Brake• Pad Wear Inspection

Refer to the Brakes in the Periodic Maintenance chapter.

BRAKES 12-15

Master Cylinder

Front• Master Cylinder Removal

•Disconnect the front brake light switch connectors [A]. Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder [C] (see Brake Hose Removal/Installation).

•Unscrew the clamp bolts [A], and take off the master cylinder as an assembly with the reservoir, brake lever, and brake switch installed.

Front• Master Cylinder Installation

Install the front master cylinder so that the punch mark [A] of the handlebar is aligned with the mating surface [B] of the master cylinder clamp to level the reservoir.

•The master cylinder clamp must be installed with the ar-

•row mark [A] upward.

Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. There will be a gap at the lower part of the clamp after tightening.

•Replace the washers on each side of the hose fitting with

•new ones.

Tighten the brake hose banjo bolt.

•Bleed the brake line (see Brake Line Bleeding in the Pe-

•riodic Maintenance chapter).

Check the brake for good braking power, no brake drag, and no fluid leakage.Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)