Disc Brakes Rear Wheel Front Disc Brakes System
Contents
1. When installing the cups do not allow the lips to turn inside out Refer to the drawing Note the installing direction of the snap ring Be certain that the snap ring is seated firmly in the groove Master cylinder Master cylinder Primary cup Spring Secondary cup Snap ring PRs Master cylinder Spring Master piston Primary cup Install the rubber boot in the groove properly Master cylinder installation Install the front rear master cylinder to the handle bar NOTE Install the holder with its UP mark facing upwards and align the holder joint with the punch mark on the handle bar Tighten the holder upper bolt first 14 10 a Front master cylinder o E Brake System Inatall the brake hose to the master cylinder with 2 new sealing washers and the hose bolt Torque 3 5kgf m Rear master cylinder Connest the brake stop switch wire Fill the brake fluid and bleed air Front master cylinder Rear master cylinder Install the rear handle cover 4 8 Install the front handle cover 4 8 Install the back mirror 14 11 MEMO2. hose bolt Torque 3 5kgf m Install the slide pin cap Fill the brake fluid and bleed air Front brake caliper 0 o SS Rear brake caliper removal Remove the brake oil bolt and the brake hose from the brake caliper Remove the EX muffler 4 9 Remove the brake caliper from the rear swing arm and remove the pad spring hanger pin and brake pad Rear brake caliper installation Install the brake caliper to the rear swing arm and connect the brake hose to the caliper and install 2 sealing washers and the brake hose bolt Torque 3 5kgf m Install the EX muffler 4 9 Install the slide pin cap Fill the brake fluid and bleed air 14 8 Brake System Master Cylinder Removal Remove the back mirror Remove the front handle cover 4 8 Remove the the rear handle cover 4 8 Disconnect the front brake switch wire Drain the brake fluid Remove the front rear brake hoses from the master cylinders CAUTION Front master cylinder Rear master cylinder Brake fluid causes damage to the painted plastic or rubber parts Do not spill fluid on these parts If contaminated gently wipe off the fluid with a piece of cloth or wash in water Close hose joints properly to prevent leakage of brake fluid Clean the disassembled parts with brake fluid and use compressed air to verify each passage is not clogged Do not allow the disassembled parts to be contaminated by waste mate
3. rear wheel mud guard Remove the rear wheel lc aay Rear caliper Rear axle nut Rear swing arm Inspection Turn the wheel and check the rim for wobbles Service limit Radical 2 0mm 0 08in Axial 2 0mm 0 08in Installation Insert the rear wheel over the drive shaft Rear Wheel Brake Suspension Install the rear wheel inside collar Install the rear swing arm tighten the rear axle nut Torque value 6 0 8 0kgf m 60 80N m 43 58ft Ib Rear wheel E Install the rear caliper assembly to the rear swing arm Install the muffler 4 9 Rear Cushion Removal Remove the body cover 4 6 Remove the luggage box 4 5 Loosen the top and bottom rear cushion setting bolts NOTE Support the frame firmly prior to working Disassembly Install the compressor attachment as shown in Cushion compressor the figure Install the cushion on the cushion compressor and compress the spring Tools Rear cushion compressor attachment Rear compressor Compressor attachment 13 4 Fix the bottom metal and loosen the lock nut Remove the bottom metal Remove the lock nut bottom metal stopper rubber spring and spring guide from the damper component Inspection Measure the rear cushion spring free length Check the damper rod for deflection or damage Service limit 238mm Assembly Assemble the spring spring guide and st
4. Rear Wheel Brake Suspension 13 Rear Wheel Brake Suspension Service Information 13 1 Rear Cushion 13 4 Troubleshooting 13 2 Rear Swing Arm 13 7 Rear Wheel 13 3 Service Information General Safety If the brake drum or lining is contaminated with oil braking power will be lost If contaminated with oil clean the brake drum and replace the brake shoe Specifications Unit mm in Item Standard value Service limit Axle shaft run out 0 2 0 008 Rear wheel rim runout Sadica f 2010 08 Axial 2 0 0 08 Rear cushion spring free length 245 238 Torque values Rear axle nut 6 0 8 0kg m 60 80N m 43 58ft lb Rear cushion upper bolt 2 7kg m 27N m 20ft lb Rear cushion lower bolt 4 0kg m 40N m 29ft lb 13 1 Rear Wheel Brake Suspension Troubleshooting Wobble or vibration in motorcycle Tire pressure incorrect Faulty tire Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Shock absorber improperly adjusted Hard suspension Shock absorber improperly adjusted Bent shock absorber rod Suspension noise Loose fasteners Worn shock 13 2 Rear Wheel Brake Suspension Rear Wheel Removal Support the motorcycle on the main stand Remove the muffler 4 9 Remove the rear caliper assembly from the rear swing arm Muffler Loosen the rear axle nut remove the rear swing arm Remove the rear wheel inside collar Remove the
5. ad pin bolt Fixing Bolt A 14 3 Brake System Remove the brake caliper from the right front fork To install a new brake pad into the brake press the piston to return to the original position Remove the pad pin bolt lock plate and brake pad Verify that the pad spring is installed in specific position Install a new brake pad lock plate and pad pin bolt 14 4 Install the brake caliper into the right front fork NOTE Be careful not to damage the brake pad Tighten the caliper braket bolt Torque 2 7kg m 27N m 19ft Ib Install pad pin bolt Torque 1 8kg m 18N m 13ft Ib Bend the lock plate tangs and fix the pad pin bolt Rear brake pad replacement NOTE When replacing brake pads replace whole set Do not remove the brake hose when replacing brake pads Open the lock plate tangs and loosen the pad pin bolt Remove the EX muffler 4 9 Remove the rear brake caliper from the rear swing arm To install a new brake pad into the brake press the piston to return to the original position Remove the pad pin bolt lock plate and brake pad Verify that the pad spring is installed in specific position Install a new brake pad lock plate and pad pin bolt Install in the reverse order of removal Brake System EN Brake caliper Pin bolt a 14 5 Brake System Brake Disk Inspectio
6. aster cylinder Brake Fluid Bleeding Brake hose bolt Front brake CAUTION A contaminated disk or pad reduces braking power Do not allow the disk or pad to be contaminated by oil Replace contaminated pads and remove pollutants from the disk completely NOTE Check the brake fluid level often and replenish new fluid as required Do not spill fluid on painted plastic or rubber parts Remove the front handle cover 4 8 Remove the master cylinder cap set plate and diaphragm from the master cylinder Connect the bleeder hose to the bleeder valve Loosen the bleeder valve and pump the brake lever repeatedly When there is no more fluid flowing out of the bleeder valve stop pumping the brake lever Air Bleeding Fill the reservoir with DOT3 or 4 brake fluid up to the upper level CAUTION To prevent chemical changes do not use different types of brake fluid Connect the recommended brake bleeder to the bleeder valve Loosen the bleeder valve while pumping the brake lever Repeat this operation until the brake fluid flows out of the brake bleeder Add brake fluid NOTE Check fluid level often and replenish fluid if the amount of fluid is reduced to the lower level Read the user s manual carefully prior to disassembling or using the brake bleeder Protect the bleeder valve with tape to prevent air from entering the bleeder valve Repeat the a
7. bove operation until there is no air flowing out of the bleeder hose Squeeze the bleeder valve and operate the brake lever to check the ingress of air 14 2 Brake System If the brake bleeder is not used do the following First fill the brake fluid up to the upper limit line Connect the hose to the bleeder valve to receive brake fluid Squeeze the brake lever completely loosen the bleeder valve 1 2 turn and tighten it again NOTE Do not release the brake lever until the bleeder valve is tightened Release the brake lever slowly to its fullest extent and leave it unattended for a few seconds Repeat the process specified in item and until there is no more air bubbles coming out of the bleeder valve Check the fluid level often and add fluid if the fluid level is near the lower level If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Assemble the bleeder valve Torque 0 4 0 7kgf m Add brake fluid up to upper level Install diaphragm and mater cylinder cap Torque value 0 1 0 2kgf m Rear brake Change in the same method as that of front brake fluid changing Bleed in the same method as that of front brake air bleeding Brake Pad Front brake pad replacement NOTE When replacing brake pads replace whole set Do not remove the brake hose when replacing brake pads Open the lock plate tangs and loosen the p
8. chemical changes do not mix different types of brake fluid Do not use the old brake fluid again Brake fluid can cause damage to painted plastic and rubber surfaces Take precautions not to allow parts to be contaminated by the brake fluid Do not reuse sealing washers Clean the disassembled parts with brake fluid and check for any clogged passage with compressed air Bleed the brake hose after removing it Troubleshooting Braking power unsatisfactory Air in the brake system Moisture in brake fluid Brake pad and disk contaminated Caliper piston seal worn Master cylinder piston seal worn Brake pad worn Caliper inside contaminated Unsatisfactory caliper sliding part operation Lopsided wear of brake pad and disk Low brake fluid level Clogged brake fluid line Disk bent or distorted Caliper piston seized or worn Master cylinder piston seized or worn Disk worn Master cylinder inside contaminated Brake lever bent 14 1 Hard brake lever movement or unsatisfactory return Brake system clogged Caliper piston seized or worn Unsatisfactory caliper sliding part operation Brake fluid line clogged Caliper piston seal worn Master cylinder piston seized or worn Brake lever bent Brake drag Brake pad and disk contaminated Improper wheel alignment Lopsided wear of brake pad and disk Disk bent or distorted Unsatisfactory caliper sliding part operation Hydraulic system contaminated with dust Brake System Front m
9. he piston and the inside of the caliper and remove the oil from the seal groove Front brake caliper inspection Caliper cylinder Check the caliper cylinder bore for scoring scratches or other damage Caliper piston Check the caliper piston O D part for scratches or other damage Front brake caliper installation Clean the piston seal and the dust seal with the brake fouid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad NOTE Brake System Make sure that each part is free from dust or dirt before reassembly Replace the dust seals and piston seals as a set whenever they are removed When cleaning with the brake fluid use the specified brake fluid Tongued A washer gt CO a Rear bracket fme pin bush Et oO pin Slide pin hanger a Pad spring Z a Q Dust seal rN Piston seal ly Piston 14 7 Brake System Apply the silicone grease to the pin bush Connect the pin bush to the portion of the caliper Install the pad spring in the caliper Install the caliper pin bolt and the slide pin in the caliper Install the brake pad and the hanger pin in the caliper Install the plug dust in the slide pin Install the brake caliper to the front fork and connect the brake hose to the caliper and install 2 sealing washers and the brake
10. n Measure the thickness of the disks Thickness 3 0mm 0 1181in Check the brake disks for vibration Service limit 0 02mm 0 0008in Brake Caliper Front brake caliper removal Remove the brake oil bolt and the brake hose from the brake caliper Remove the caliper from the R front fork and remove the pad spring hanger pin and brake pad CAUTION Pay attention not to let the brake fluid adhere to the parts because it can damage the painted surface Wind the hose joint with cloth to prevent the brake fluid from leaking Clean the removed parts with the brake fluid and make sure that the each port isn t clogged with the compressed air Keep the removed parts in order to avoid dust from adhering Front brake caliper disassembly Remove the slide pin the L bracket the pin bush the boot and the pin boot and the pin bolt from the caliper If there is any wear or damage in the boot replace it with the new one Wind the caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston from the caliper while SSS blowing the low pressure air in the opening of Caliper the brake hose 14 6 CAUTION Never use the high pressure air or bring the air gun too close Never touch the inside of the caliper Disassemble the piston seal and the dust seal NOTE Pay attention not to damage the inner surface of the caliper Clean t
11. opper rubber NOTE Install the spring with its narrow pitch side facing upward Apply thread locking agent to the lock nut and install the rear cushion compressor attachment on the damper rod Fix the upper joint and tighten the lock nut Torque value 2 0kg m 20N m 14ft Ib Tools Rear compressor Rear cushion compressor attachment Installation Assemble the rear cushion Tighten the top and bottom of the cushion with bolt Torque value Upper side 2 7kg m 27N m 20ft Ib Lower side 4 0kg m 40 N m 29ft Ib Rear Wheel Brake Suspension Bottom metal Compressor attachment 13 5 Rear Wheel Brake Suspension Rear Swing Arm Removal Remove the following parts EX muffler 4 9 Rear brake caliper Loosen the axle nut remove the rear swing arm Disassemble the rear wheel outside collar to the rear swing arm Disassemble the oil seal and radial ball bearing Install in the reverse order of removal Torque value Rear wheel axle nut 6 0 8 0kgf m Oo Fey cg v l A L Rear brake caliper mA AS Rear swing arm 13 6 Brake System 14 Brake System Service Information 14 1 Troubleshooting 14 1 Brake Fluid Bleeding 14 2 Brake Pad 14 3 Brake Disk 14 6 Brake Caliper 14 6 Master Cylinder 14 9 Service Information General Safety Do not allow foreign material to enter the system when replenishing brake fluid To prevent
12. rial or dust Remove the front rear master cylinder holder and lift out the master cylinder Disassembly Remove the front rear stop switch Disassemble the piston boot cir clip from the master cylinder TOOL SNAP RING PLIERS Disassemble the washer piston spring from the master cylinder Clean the master cylinder reserve master piston with the recommended brake fluid Master cylinder inspection Check the piston periphery for kink or scratch Check the primary and secondary cups for wear Master cylinder 14 9 Brake System NOTE If there is any leak of fluid when installing new piston it may indicate the side wear of the cylinder by the direction of the piston contacting face In this case the master cylinder must be replaced also Chack the master cylinder for scores scratches or nicks and replace if necessary Master cylinder assembly CAUTION Replace the piston spring cups and snap ring as a set Be sure that each part is free from dust or dirt before reassembly When cleaning with the brake fluid use the specified brake fluid Coat the piston cup with the fresh brake fluid and install it on the piston Install the spring with its larger diameter end toward the master cylinder Install the primary cup with its concaved side toward the inner side of the master cylinder Install the snap ring TOOL SNAP RING PLIERS CAUTION
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