HYDRAULIC BRAKE
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Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with high quality brake degreasing agent.
• Check the brake system by applying the brake lever or pedal after the air bleeding.
• Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they may not be compatible.
• Always check brake operation before riding the motorcycle.
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Unit: mm (in |
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ITEM |
STANDARD |
SERVICE LIMIT |
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Front |
Brake fluid |
DOT 4 |
- |
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Brake disc thickness |
3.0 (0.12) |
2.5(0.10) |
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Brake disc warpage |
- |
0.15 (0.006) |
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Master cylinder I. D. |
11.000(0.4331) |
11.050 (0.4350) |
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Master piston O. D. |
10.971 (0.4319) |
10.840 (0.4268) |
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Caliper cylinder I. D. |
27.025 (1.0640) |
27.060 (1.0654) |
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Caliper piston O. D. |
26.968 (1.0617) |
26.853 (1.0572) |
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Rear |
Brake fluid |
DOT 4 |
- |
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Brake disc thickness |
4.0(0.16) |
3.5(0.14) |
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Brake disc warpage |
- |
0.15 (0.006) |
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Master cylinder I. D. |
9.547 (0.3759) |
9.575 (0.3770) |
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Master piston O. D. |
9.491 (0.3737) |
9.465 (0.3726) |
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Caliper cylinder I. D. |
22.650 (0.8917) |
22.712 (0.8942) |
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Caliper piston O. D. |
22.620 (0.8905) |
22.573 (0.8887) |
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Brake pedal push rod standard length |
79.6 mm (3.13 in) |
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Brake hose oil bolt Brake lever pivot nut Brake lever pivot bolt Brake lever adjuster lock nut Front master cylinder reservoir cover screw Front master cylinder holder bolt Front brake caliper mounting bolt Front/rear caliper bleed valve Rear master cylinder reservoir cover bolt Rear master cylinder mounting bolt Brake caliper pad pin Front brake caliper pad pin plug Brake pedal pivot bolt Brake pedal adjuster lock nut Front brake disc cover bolt |
34 N m (3.5 kgf-m, 25 Ibf-ft)
5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft)
1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft)
5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft)
1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft)
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Apply locking agent to the threads |
9.9 N-m (1.0 kgf-m, 7.3 Ibf-ft) 30 N-m (3.1 kgf-m, 22 Ibf-ft) 5.4 N-m (0.6 kgf-m, 4.0 Ibf-ft)
1.0 N-m (0.1 kgf-m, 0.7 Ibf-ft) 13 N-m (1.3 kgf-m, 10 Ibf-ft) 18 N-m (1.8 kgf-m, 13 Ibf-ft)
2 N-m (0.2 kgf-m, 1.5 Ibf-ft) 36 N-m (3.7 kgf-m, 27 Ibf-ft)
5.9 N-m (0.6 kgf-m, 4.4 Ibf-ft) 13 N-m (1.3 kgf-m, 10 Ibf-ft)
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Brake lever/pedal soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pads/disc
• Worn caliper piston seal
• Worn master cylinder piston cups
• Worn brake pads/disc
• Contaminated caliper
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Contaminated master cylinder
• Bent brake lever/pedal
Brake lever/pedal hard
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Caliper not sliding properly
• Clogged/restricted fluid passage
• Worn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever/pedal
Brake drags
• Contaminated brake pads/disc
• Misaligned wheel
• Clogged/restricted brake hose joint
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted brake hydraulic system
• Sticking/worn caliper piston
• Clogged master cylinder port
