Page 175 of 457
4-28
A
B
A
B
BA
FRONT AND REAR BRAKESCHAS
EAS00593
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of the
brake master cylinders.
1. Check:
brake master cylinder
Damage / scratches / wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
AFront
BRear
2. Check:
brake master cylinder kit
Damage / scratches / wear Replace.
AFront
BRear
3. Check:
brake fluid reservoir
1
Cracks / damage Replace.
brake fluid reservoir diaphragm
2
Cracks / damage Replace.
AFront
BRear
4. Check:
brake hoses
Cracks / damage / wear Replace.
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Page 176 of 457
4-29
FRONT AND REAR BRAKESCHAS
WARNING
13 Nm (1.3 mkg, 9.4 ftlb)
NOTE:
30 Nm (3.0 mkg, 22 ftlb)
WARNING
EAS00607
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake com-
ponents.
Recommended brake fluid
DOT 4
1. Install :
brake master cylinder kit
circlip
New
dust boot
2. Install:
brake master cylinder
1
Install the brake master cylinder holder with
the “UP” mark
a facing up.
Align the end of the brake master cylinder
holder with the punch mark
b on the right han-
dlebar.
First, tighten the upper bolt, then the lower bolt.
There should be 2 2.5 mm (0.08 0.10 in)
for clearance between the right handlebar
switch and the brake master cylinder holder.
3. Install:
copper washers
New
brake hose
union bolt
brake light switch coupler
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
ProCarManuals.com
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
ProCarManuals.com
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
ProCarManuals.com
Page 181 of 457
4-34
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake
calipers
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw2
1
1
2
4
8
1Disassemble the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
For assembly, reverse the disassembly
procedure.
NOTE:
1
2
3
4
5
6
7
5 Nm (0.5 mkg, 3.6 ftlb)
EAS00615
ProCarManuals.com
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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