Page 177 of 457
4-30
FRONT AND REAR BRAKESCHAS
NOTE:
WARNING
CAUTION:
While holding the brake hose, tighten the
union bolt.
Turn the handlebars to the left and right to
make sure the brake hose does not touch oth-
er parts (e.g., wire harness, cables, leads).
Correct if necessary.
4. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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Page 178 of 457
4-31
FRONT AND REAR BRAKESCHAS
30 Nm (3.0 mkg, 22 ftlb)
WARNING
CAUTION:
6. Check:
brake fluid level
Below the minimum level mark
a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
brake master cylinder kit
circlip
dust boot
2. Install:
copper washers
New
brake hoses
union bolt
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection
a as shown.
3. Fill:
brake fluid reservoir
(to the maximum level mark
b)
Recommended brake fluid
DOT 4
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Page 179 of 457
4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
brake fluid level
Below the minimum level mark
a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
ProCarManuals.com
Page 180 of 457
4-33
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the front brake calipers
Brake fluid
Union bolt
Copper washer
brake hose
brake caliper1
2
1
1Remove the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal
procedure.
NOTE:
6 Nm (0.6 mkg, 4.3 ftlb)
30 Nm (3.0 mkg, 22 ftlb)
35 Nm (3.5 mkg, 25 ftlb)
EAS00613
FRONT BRAKE CALIPERS
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Page 182 of 457
4-35
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 mkg, 22 ftlb)
27 Nm (2.7 mkg, 20 ftlb)22 Nm (2.2 mkg, 16 ftlb)
EAS00616
REAR BRAKE CALIPER
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Page 184 of 457
4-37
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
union bolt
1
copper washers 2
brake hose 3
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons
1
brake caliper piston seals 2
a. Secure the brake caliper pistons with a piece
of wood
a.
b. Blow compressed air into the brake hose
joint opening
b to force out the left side pis-
tons from the brake caliper.
Never try to pry out the brake caliper pis-
tons.
Do not loosen the bolts
3.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
ProCarManuals.com
Page 185 of 457
4-38
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
union bolt
1
copper washers 2
brake hose 3
brake caliper 4
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper piston
1
brake caliper piston seals 2
a. Secure the brake caliper piston with a piece
of wood
a.
b. Blow compressed air into the brake hose
joint opening
b to force out the piston from
the brake caliper.
Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Never try to pry out the brake caliper pis-
ton.
c. Remove the brake caliper piston seals.
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Page 186 of 457
4-39
A
B
FRONT AND REAR BRAKESCHAS
WARNING
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
p
replacement schedule
Brake padsIf necessary
Piston sealsEvery two years
Brake hosesEvery four years
Brake fluidEvery two years
and whenever the
brake is disas-
sembled
1. Check:
brake caliper pistons
1
Rust / scratches / wear Replace the brake
caliper pistons.
brake caliper cylinders
2
Scratches / wear Replace the brake cali-
per assembly.
brake caliper body
3
Cracks / damage Replace the brake cali-
per assembly.
brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed air.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
AFront
BRear
2. Check:
brake caliper bracket
1
Cracks / damage Replace.
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