Bao Duong Xe Airblade

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  • 8/13/2019 Bao Duong Xe Airblade

    1/2016-

    16. BRAKE SYSTEM

    COMPONENT LOCATION16-2

    SERVICE INFORMATION16-3

    TROUBLESHOOTING16-5

    REAR DRUM BRAKE 16-6

    BRAKE FLUID REPLACEMENT/AIR BLEEDING 16-7

    BRAKE PAD/DISC16-9

    BRAKE MASTER CYLINDER16-12

    COMBINED BRAKE EQUALIZER(CBS TYPE)16-16

    BRAKE CALIPER 16-19

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    BRAKE SYSTEM

    16-2

    BRAKE SYSTEM

    COMPONENT LOCATIONFRONT DISC BRAKE

    STANDARD TYPE

    COMBINED BRAKE SYSTEM (CBS) TYPE

    REAR DRUM BRAKE

    34 Nm (3.5 kgfm, 25 lbfft)

    30.4 Nm (3.1 kgfm, 22 lbfft)

    34 Nm (3.5 kgfm, 25 lbfft)

    34 Nm (3.5 kgfm, 25 lbfft)

    30.4 Nm (3.1 kgfm, 22 lbfft)

    34 Nm (3.5 kgfm, 25 lbfft)

    118 Nm (12.0 kgfm, 87 lbfft)

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    BRAKE SYSTE

    16-

    SERVICE INFORMATIONGENERAL

    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 master cylinder reservoir is horizontal first.

    A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc withigh quality brake degreasing agent.

    Check the brake system by applying the brake lever after the air bleeding. Never allow contaminants (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 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types

    fluid, they may not be compatible. Always check brake operation before riding the scooter.

    SPECIFICATIONS

    Unit: mm

    Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous to your heal Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

    ITEM STANDARD SERVICE LIMIT

    Brake lever freeplay 10 20 (0.4 0.8)

    Brake drum I.D. 130.0 (5.12) 131.0 (5.16)

    Specified brake fluid DOT 3 or 4

    Brake disc Thickness 3.3 3.7 (0.13 0.15) 3.0 (0.12)

    Warpage 0.10 (0.004)

    Master cylinder Cylinder I.D. 12.700 12.743 (0.5000 0.5017) 12.755 (0.5022

    Piston O.D. 12.657 12.684 (0.4983 0.4994) 12.645 (0.4978

    Caliper Cylinder I.D. 25.400 25.450 (1.0000 1.0020) 25.460 (1.0024

    Piston O.D. 25.318 25.368 (0.9968 0.9987) 25.31 (0.996)

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    BRAKE SYSTEM

    16-4

    TORQUE VALUES

    TOOL

    Rear axle nut 118 Nm (12.0 kgfm, 87 lbfft) U-nut, Apply engine oil to the threadsand seating surface

    Rear brake arm bolt 10 Nm (1.0 kgfm, 7 lbfft) ALOC bolt; replace with new one.

    Brake caliper bleed valve 5.4 Nm (0.6 kgfm, 4.4 lbfft)

    Brake master cylinder reservoir cap screw 1.5 Nm (0.2 kgfm, 1.1 lbfft)

    Brake pad pin 18 Nm (1.8 kgfm, 13 lbfft)

    Front brake lever pivot bolt(Standard type only) 1 Nm (0.1 kgfm, 0.7 lbfft)

    Front brake lever pivot screw(CBS type only)

    1 Nm (0.1 kgfm, 0.7 lbfft)

    Front brake lever pivot nut 6 Nm (0.6 kgfm, 4.4 lbfft)

    Front brake light switch screw 1 Nm (0.1 kgfm, 0.7 lbfft)

    Brake hose oil bolt 34 Nm (3.5 kgfm, 25 lbfft)

    Brake caliper mounting bolt 30.4 Nm (3.1 kgfm, 22 lbfft) ALOC bolt; replace with new ones.

    Rear brake lever pivot screw(CBS type only)

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    Rear brake lever pivot nut(CBS type only)

    5.2 Nm (0.5 kgfm, 3.8 lbfft) U-nut

    Equalizer rod pivot screw(CBS type only)

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    Equalizer rod pivot nut

    (CBS type only)

    5.2 Nm (0.5 kgfm, 3.8 lbfft) U-nut

    Rear brake lever bracket cover screw(CBS type only)

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    Rear brake lever bracket cover special screw(CBS type only)

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    Brake caliper torque pin 22 Nm (2.2 kgfm, 16 lbfft)

    Brake caliper pin 18 Nm (1.8 kgfm, 13 lbfft)

    Equalizer connecting cable lock nut(CBS type only)

    6.4 Nm (0.7 kgfm, 4.7 lbfft)

    Snap ring pliers

    07914-SA50001

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    BRAKE SYSTE

    16-

    TROUBLESHOOTINGPoor rear brake performance Incorrect adjustment of rear brake lever Contaminated brake shoes Worn brake shoes Worn brake cam Worn brake drum Improperly installed brake arm

    Improperly engaged brake arm serrations

    Brake lever soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad/disc Worn caliper piston seals Worn master cylinder piston cups Worn brake pad/disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston

    Sticking/worn master cylinder piston Bent brake lever

    Brake lever hard Clogged/restricted brake system Sticking/worn caliper piston Caliper not sliding properly Worn caliper piston seal Sticking/worn master cylinder piston Bent brake lever

    Brake drags Contaminated brake pad/disc Misaligned wheel Badly worn brake pad/disc Warped/deformed brake disc

    Caliper not sliding properly Clogged/restricted fluid passage Sticking caliper piston Improperly adjusted connecting cable (CBS type only)

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    BRAKE SYSTEM

    16-6

    REAR DRUM BRAKEDISASSEMBLY/ASSEMBLY

    Always replace the brake shoes as a set. Mark all parts during disassembly so they can be

    placed back in the original locations.

    Remove the rear wheel (page 15-5).

    Remove the adjusting nut and brake cable from the jointpin.Remove the joint pin and return spring.

    Expand the brake shoes and remove the brake shoes/shoe springs from the brake panel.Remove the following:

    Brake arm bolt Brake arm/brake cam Dust seals

    Install the removed parts in the reverse order ofremoval.

    Apply grease to the new dust seals, brake camsliding surface and brake shoe contacting area.

    Replace the dust seals and brake arm bolt with newones.

    Adjust the rear brake lever freeplay (page 4-17).

    TORQUE:BRAKE ARM BOLT

    10 Nm (1.0 kgfm, 7 lbfft)

    Set the return spring ends into the hole

    on the left crankcase and onto the pin

    on the brake arm.

    DUST SEALS

    BRAKE CAM BRAKE SHOES

    RETURN SPRING

    BRAKE ARM BOLT

    10 Nm (1.0 kgfm, 7 lbfft)

    SHOE SPRINGS

    BRAKE ARM

    ADJUSTING NUT

    JOINT PIN

    *: Apply each 0.2 - 0.3 g of grease.

    *

    *Align

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    BRAKE SYSTE

    16-

    INSPECTION

    Measure the rear brake drum I.D.

    BRAKE FLUID REPLACEMENT/AIR BLEEDING

    BRAKE FLUID DRAINING

    Do not mix different types of fluid, as they are not

    compatible with each other. Do not allow foreign material to enter the systemwhen filling the reservoir.

    Spilled fluid can damage painted, plastic or rubberparts. Place a rag over these parts whenever thesystem is serviced.

    Turn the handlebar until the reservoir is parallel to theground before removing the reservoir cap.

    Remove the screws, reservoir cap, diaphragm plateand diaphragm.

    Connect a bleed hose to the caliper bleed valve.

    Loosen the bleed valve and pump the brake lever untilno more fluid flows out of the bleed valve.

    SERVICE LIMIT: 131.0 mm (5.16 in)

    RESERVOIR CAP

    DIAPHRAGM

    PLATEDIAPHRAGM

    SCREWS

    BLEED VALVE BLEED HOS

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    BRAKE SYSTEM

    16-8

    BRAKE FLUID FILLING/AIR BLEEDING

    Do not mix different

    types of fluid. They

    are not compatible.

    Fill the master cylinder reservoir with DOT 3 or DOT 4brake fluid from the sealed container to the upper level.

    Check the fluid level often while bleeding the braketo prevent air from being pumped into the system.

    Connect a commercially available brake bleeder to thebleed valve.

    Operate the brake bleeder and loosen the bleed valve.

    If the brake bleeder is not available, perform thefollowing procedure.

    Pump up the system pressure with the brake lever untilthe lever resistance is felt.

    Check the fluid

    level often while

    bleeding the brake

    to prevent air from

    being pumped into

    the system.

    Do not release thebrake lever until the

    bleed valve has

    been closed.

    Connect a bleed hose to the bleed valve and bleed thesystem as follows:

    1. Squeeze the brake lever all the way and loosen thebleed valve 1/2 of a turn. Wait several seconds andthen close the bleed valve.

    2. Release the brake lever slowly and wait several

    seconds after it reaches the end of its travel.3. Repeat the steps 1 and 2 until there are no air

    bubbles in the bleed hose.

    After bleeding the system completely, tighten the bleedvalve to the specified torque.

    UPPER LEVEL

    If air enters the

    bleeder from

    around the bleed

    valve threads, sealthe threads with

    teflon tape.

    Check the fluid level

    often while bleeding

    the brake to prevent

    air from being

    pumped into the

    system.

    BLEED VALVE

    TORQUE:5.4 Nm (0.6 kgfm, 4.4 lbfft)

    BLEED VALVE BLEED HOSE

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    BRAKE SYSTE

    16-

    Do not mix different

    types of fluid. They

    are not compatible.

    Fill the reservoir to the upper level with DOT 3 or DOT 4brake fluid from a sealed container.

    Install the diaphragm, diaphragm plate and reservoircap, then tighten the screws to the specified torque.

    BRAKE PAD/DISCBRAKE PAD REPLACEMENT

    Check the brake

    fluid level in the

    reservoir as this

    operation causes

    the level to rise.

    Push the caliper pistons all the way in to allowinstallation of new brake pads.

    Remove the pad pin from the brake caliper.

    Remove the O-ring from the pad pin.

    UPPER LEVE

    TORQUE:1.5 Nm (0.2 kgfm, 1.1 lbfft)

    RESERVOIR CAP

    DIAPHRAGM

    PLATE DIAPHRAGM

    SCREWS

    BRAKE CALIPER

    PAD PIN / O-RING

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    BRAKE SYSTEM

    16-10

    Remove the brake pads from the brake caliper.

    Always replace the

    brake pads in pairs

    to assure even disc

    pressure.

    Install new brake pads so that they are set on the brakecaliper bracket and bracket pin.

    Apply silicon grease to the new O-ring and install it tothe pad pin.

    Install the pad pin by pushing the brake pads againstthe pad spring to align the pad pin holes on the padsand caliper hole.

    After the brake pad

    replacement, check

    the brake operation

    by applying the

    brake lever.

    Tighten the pad pin to the specified torque.

    BRAKE

    PADS

    BRAKE

    PADS

    Set the pads BRACKET PIN

    PAD PIN

    O-RING

    TORQUE:18 Nm (1.8 kgfm, 13 lbfft)

    PAD PIN

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    BRAKE SYSTE

    16-1

    BRAKE DISC INSPECTION

    Visually inspect the brake disc for damage or cracks.

    Measure the brake disc thickness at several points.

    Check the brake disc for warpage.

    If the warpage exceeds the service limit, check thewheel bearings for excessive play.

    For brake disc replacement, refer to page 14-8.

    SERVICE LIMIT: 3.0 mm (0.12 in)

    SERVICE LIMIT: 0.10 mm (0.004 in)

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    BRAKE SYSTEM

    16-12

    BRAKE MASTER CYLINDERREMOVAL/INSTALLATION

    STANDARD TYPE

    Drain the brake fluid (page 16-7).Remove the rear handlebar cover (page 3-8).

    Disconnect the front brake light switch wire (Green/

    Yellow, Black) connectors.Remove the oil bolt, brake hose and sealing washers.

    Install the removed parts in the reverse order ofremoval.

    Replace the sealing washers with new ones. Fill and air bleed the hydraulic system (page 16-7).

    CBS TYPE

    Drain the brake fluid (page 16-7).

    Remove the rear handlebar cover (page 3-8).Loosen the rear brake adjusting nut until the play of thebrake cable becomes maximum.

    TORQUE:OIL BOLT

    34 Nm (3.5 kgfm, 25 lbfft)

    OIL BOLT

    34 Nm (3.5 kgfm, 25 lbfft)

    BRAKE HOSE

    WIRE (Green/Yellow, Black)

    CONNECTORS

    MASTER CYLINDER

    DIAPHRAGM

    DIAPHRAGM PLATE

    RESERVOIR CAP

    SCREW

    1.5 Nm (0.2 kgfm, 1.1 lbfft)BOLTS

    SEALING WASHERS

    Set the brake hose

    eyelet against the

    stopper.

    Set the holder with

    its "UP" mark facing

    up.

    Tighten the upper

    bolt first, then the

    lower bolt.

    Align the end of master

    cylinder with the punch

    mark on handlebar.

    HOLDER

    ADJUSTING NUT

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    BRAKE SYSTE

    16-1

    Loosen the lock nut and turn the adjuster until the playof the connecting cable becomes maximum.

    Compress the return spring and disconnect the tip ofthe connecting cable from the knocker joint.Remove the return spring.Remove the connecting cable.

    Remove the master cylinder (page 16-12).

    Install the master cylinder (page 16-12).

    Install the connecting cable to the master cylinder.Turn in the adjuster completely.Set the return spring on the connecting cable.Compress the return spring and connect the tip of theconnecting cable to the knocker joint.

    Fill and air bleed the hydraulic system (page 16-7).

    Turn the adjuster until the edge surface of the knockerseats on the edge surface of the master cylinder body.

    Check that there is no gap between the knocker pin andthe end of the slot of the knocker joint.

    If there is any gap, turn the adjuster until there is no gapbetween the knocker pin and the end of the slot of theknocker joint.

    After adjustment, hold the adjuster and tighten the locknut to the specified torque.

    After tightening the lock nut, check that there is no gapbetween the knocker pin and the end of the slot of theknocker joint.

    Apply rear brake lever several times and check that thedistance between the edges has not been changedafter applying the brake.

    Recheck the edge surface of the knocker seats on theedge surface of the master cylinder body.

    Adjust the rear brake lever freeplay (page 4-17).Install the rear handlebar cover (page 3-8).

    LOCK NUT

    CONNECTING

    CABLE

    ADJUSTERRETURN

    SPRING

    KNOCKER

    JOINT

    INSPECTION

    POINT

    KNOCKER

    ADJUSTER

    CONNECTING

    CABLE

    RETURN

    SPRING

    TORQUE:6.4 Nm (0.7 kgfm, 4.7 lbfft)

    KNOCKER JOINT

    KNOCKER PIN

    LOCK NUT ADJUSTER

    INSPECTION

    POINT

    KNOCKER

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    BRAKE SYSTEM

    16-14

    DISASSEMBLY/ASSEMBLY

    STANDARD TYPE

    Remove/install the following:

    Brake lever pivot nut, bolt and brake lever Screw and brake light switch Boot

    Remove/install the snap ring using the special tool.

    Remove/install the washer, master piston and spring.

    Keep the piston, cups, spring, snap ring and boot asa set; do not substitute individual parts.

    When installing the cups, do not allow the lips to turn

    inside out. Be sure that snap ring is firmly seated in the groove. Apply silicone grease to the pivot bolt sliding

    surface, boots inside and lever to piston contactarea.

    Apply brake fluid to master piston, piston cups andspring.

    TOOL:

    Snap ring pliers 07914-SA50001

    TORQUE:FRONT BRAKE LEVER PIVOT BOLT

    1 Nm (0.1 kgfm, 0.7 lbfft)

    FRONT BRAKE LEVER PIVOT NUT

    6 Nm (0.6 kgfm, 4.4 lbfft)

    FRONT BRAKE LIGHT SWITCH SCREW

    1 Nm (0.1 kgfm, 0.7 lbfft)

    SNAP RING PLIERS

    SNAP RING

    BRAKE LEVER

    PIVOT NUT

    6 Nm (0.6 kgfm, 4.4 lbfft)SCREW

    1 Nm (0.1 kgfm, 0.7 lbfft)

    BRAKE LIGHT

    SWITCH

    MASTER

    CYLINDER BODY

    *: Apply 0.1 g of silicone grease

    MASTER PISTON

    SNAP RING

    WASHER PISTON CUPS

    SPRING

    BOOT

    PIVOT BOLT

    1 Nm (0.1 kgfm, 0.7 lbfft)

    *

    (Lever contact area)

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    BRAKE SYSTE

    16-1

    CBS TYPE

    Remove/install the following:

    Brake lever pivot nut/screw/brake lever/knocker/return spring/spring

    Screw and brake light switch Boot

    Remove/install the snap ring using the snap ring pliers(page 16-14).Remove/install the washer, master piston and spring.

    Keep the piston, cups, spring, snap ring and boot asa set; do not substitute individual parts.

    When installing the cups, do not allow the lips to turninside out.

    Be sure that snap ring is firmly seated in the groove. Apply silicone grease to the pivot screw sliding

    surface, boots inside and lever to piston contactarea.

    Apply brake fluid to master piston, piston cups andspring.

    INSPECTION

    Check the piston cups for wear, deterioration ordamage.

    Check the master cylinder inner surface and pistonouter surface for scratches or damage.

    Measure the master cylinder I.D.

    Measure the master piston O.D.

    TORQUE:FRONT BRAKE LEVER PIVOT SCREW

    1 Nm (0.1 kgfm, 0.7 lbfft)

    FRONT BRAKE LEVER PIVOT NUT

    6 Nm (0.6 kgfm, 4.4 lbfft)

    FRONT BRAKE LIGHT SWITCH SCREW

    1 Nm (0.1 kgfm, 0.7 lbfft)

    BRAKE LEVER

    PIVOT NUT

    6 Nm (0.6 kgfm, 4.4 lbfft)SCREW

    1 Nm (0.1 kgfm, 0.7 lbfft)

    BRAKE LIGHT

    SWITCH

    MASTER

    CYLINDER BODY

    *: Apply 0.1 g of silicone grease

    MASTER PISTON

    SNAP RING WASHERPISTON CUPS

    SPRINGBOOT PIVOT SCREW

    1 Nm (0.1 kgfm, 0.7 lbfft)

    KNOCKER

    SPRING

    RETURN

    SPRING

    *(Lever contact area)

    SERVICE LIMIT: 12.755 mm (0.5022 in)

    SERVICE LIMIT: 12.645 mm (0.4978 in)

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    BRAKE SYSTEM

    16-16

    COMBINED BRAKE EQUALIZER(CBS TYPE)

    REMOVAL/INSTALLATION

    Remove the front handlebar cover (page 3-8).Disconnect the connecting cable (page 16-12).

    Remove/install the following:

    Special screw/set rubber Screws/bracket cover

    Lock lever/return spring Bolt/holder/lever bracket Brake lever pivot screw/nut Equalizer rod pivot screw/nut Brake lever Brake cable/connecting cable Brake light switch/grommet

    Apply grease to the pivot screws and equalizer sliding surface.

    Be careful when

    removing the lock

    lever. The return

    spring may pop out.

    TORQUE:BRACKET COVER SCREW

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    BRACKET COVER SPECIAL SCREW

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    REAR BRAKE LEVER PIVOT SCREW4.2 Nm (0.4 kgfm, 3.1 lbfft)

    REAR BRAKE LEVER PIVOT NUT

    5.2 Nm (0.5 kgfm, 3.8 lbfft)

    EQUALIZER ROD PIVOT SCREW

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    EQUALIZER ROD PIVOT NUT

    5.2 Nm (0.5 kgfm, 3.8 lbfft)

    BOOT GROMMET

    SCREWS

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    BRAKE LEVER

    HOLDER

    BOLT

    BRAKE LEVER BRACKET

    SPECIAL SCREW

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    BRACKET

    COVER

    SET RUBBER

    CONNECTING CABLE

    EQUALIZER

    BRAKE CABLE

    BRAKE LIGHT SWITCH

    BRAKE LEVER PIVOT SCREW

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    EQUALIZER ROD PIVOT SCREW

    4.2 Nm (0.4 kgfm, 3.1 lbfft)

    PIVOT NUTS

    5.2 Nm (0.5 kgfm, 3.8 lbfft)

    Install the spring as shown:

    LOCK LEVER

    RETURN

    SPRING

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    BRAKE SYSTE

    16-1

    Install the rear brake light switch while aligning its tabwith the groove on rear brake lever bracket.

    Connect the brake light switch wire connectors.

    Apply grease to the sliding surface of the equalizer.

    Install the boot grommet over the equalizer.

    Connect the rear brake cable to the equalizer with the"F" mark of the equalizer facing up and set the rearbrake cable to the rear brake lever bracket.Connect the connecting cable to the equalizer and setthe connecting cable to the rear brake lever bracket.

    Install the equalizer boots grommet to the rear brakelever bracket.

    Set the rear brake lever to the rear brake lever bracketand the equalizer.

    Apply grease to the sliding surface of the rear brakelever pivot screw.Install and tighten the pivot screw to the specifiedtorque.

    Apply grease to the sliding surface of the equalizer rodpivot screw.Install and tighten the pivot screw to the specifiedtorque.

    Install and tighten the brake lever pivot nut to thespecified torque while holding the pivot screw.

    Install and tighten the equalizer rod pivot nut to thespecified torque while holding the pivot screw.

    Align the boss of the rear brake lever bracket with thehole of the handlebar and install the rear brake leverbracket.

    Install the bracket holder onto the handlebar by aligningthe groove of the holder and tab of the lever bracket.

    Alig

    WIRE CONNECTORS

    EQUALIZER

    BOOT

    GROMME"F" MARKCONNECTING CABLE

    BRAKE

    CABLE

    TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)

    TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)

    TORQUE:5.2 Nm (0.5 kgfm, 3.8 lbfft)

    TORQUE:5.2 Nm (0.5 kgfm, 3.8 lbfft)

    NUTS BRAKE LEVER

    EQUALIZER ROD

    PIVOT SCREWBRAKE LEVE

    PIVOT SCREW

    BRACKET HOLDER

    Align

    (Tab and hole)

    Align (Boss and hole)

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    BRAKE SYSTEM

    16-18

    Install and tighten the holder bolt.

    Set the return spring to the rear brake lock lever.Install the rear brake lock lever to the rear brake leverbracket and make sure that the return spring is set inposition as shown.

    Set the bracket cover to the rear brake lever bracketwhile holding the rear brake lock lever.Tighten the bracket cover screws to the specifiedtorque.

    Install the set rubber to the rear brake lock lever andtighten the bracket cover special screw to the specifiedtorque.

    Check the brake lock lever operation (page 4-20).Connect the connecting cable (page 16-12).

    Install the front handlebar cover (page 3-8).

    HOLDER BOLT

    LOCK LEVER

    RETURN SPRING

    TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)

    SCREWS

    BRACKET COVER LOCK LEVER

    TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)

    SET RUBBER SPECIAL SCREW

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    BRAKE SYSTE

    16-1

    BRAKE CALIPERREMOVAL

    Avoid spilling fluid

    on painted, plastic,

    or rubber parts.

    Place a shop towel

    over these parts

    whenever thesystem is serviced.

    Drain the brake fluid (page 16-7).

    Remove the following:

    Oil bolt/sealing washers Brake pads (page 16-9)

    Mounting bolts Brake caliper

    INSTALLATION

    Install the front brake caliper onto the left fork leg.Install new mounting bolts and tighten them to thespecified torque.

    Connect the brake hose to the brake caliper with the oilbolt and new sealing washers.

    Tighten the oil bolt to the specified torque.

    Install the brake pads (page 16-9).Fill the brake fluid and bleed the hydraulic system (page16-7).

    TORQUE:30.4 Nm (3.1 kgfm, 22 lbfft)

    Tighten the oil bolt

    while pushing the

    brake hose eyelet

    joint against thestopper.

    TORQUE:34 Nm (3.5 kgfm, 25 lbfft)

    BRAKE CALIPER

    BRAKE HOSE

    SEALING WASHERS

    BRAKE CALIPER MOUNTING BOLTS

    30.4 Nm (3.1 kgfm, 22 lbfft)

    OIL BOLT

    34 Nm (3.5 kgfm, 25 lbfft)

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    BRAKE SYSTEM

    DISASSEMBLY/ASSEMBLY

    Remove the following:

    Caliper bracket Pin boots Pad spring

    Place a shop towel over the piston.

    Position the caliper body with the piston facing down

    and apply small squirts of air pressure to the fluid inletto remove the piston.

    Remove the dust seal/piston seal.

    Install the removed parts in the reverse order ofremoval.

    Apply silicone grease to the dust seal and bracketpin boots.

    Apply brake fluid to the piston and piston seal. Replace the dust seal and piston seal with new ones.

    INSPECTION

    Check the caliper cylinder for scoring, scratches or

    damage.Measure the caliper cylinder I.D.

    Check the caliper piston for scoring, scratches ordamage.

    Measure the caliper piston O.D.

    Do not use high

    pressure air or bring

    the nozzle too close

    to the inlet.

    BLEED VALVE

    5.4 Nm (0.6 kgfm, 4.4 lbfft)

    CALIPER BODY

    *: Apply 0.4 g minimum of silicone grease

    CALIPER PISTON

    PAD SPRING

    BRACKET PIN BOOT

    PISTON SEAL

    CALIPER BRACKET

    DUST SEAL

    BRACKET PIN BOOT

    Install the caliper piston with

    its opened end facing the

    brake pads.

    *

    *

    SERVICE LIMIT: 25.460 mm (1.0024 in)

    SERVICE LIMIT: 25.31 mm (0.996 in)