Page 187 of 457
4-40
FRONT AND REAR BRAKESCHAS
WARNING
35 Nm (3.5 mkg, 25 ftlb)
30 Nm (3.0 mkg, 22 ftlb)
6 Nm (0.6 mkg, 4.3 ftlb)
WARNING
CAUTION:
EAS00640
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
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 as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install :
brake pads
brake pad spring
brake pad pin
2. Install:
brake caliper
1
copper washers New
brake hose
2
union bolt 3
brake hose holder
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake caliper
1, make sure the brake pipe a
touches the projection b on the brake cali-
per.
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Page 188 of 457
4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. 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.
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. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to ”BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
ProCarManuals.com
Page 189 of 457
4-42
FRONT AND REAR BRAKESCHAS
WARNING
27 Nm (2.7 mkg, 20 ftlb)
22 Nm (2.2 mkg, 16 ftlb)
30 Nm (3.0 mkg, 22 ftlb)
WARNING
CAUTION:
EAS00642
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
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 as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
brake caliper
1
(front)
(rear)
brake pad pin
screw plug
copper washers
New
brake hose
2
union bolt 3
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake caliper
1, make sure the brake pipe a
touches the projection b on the brake cali-
per.
ProCarManuals.com
Page 190 of 457
4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. 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.
3. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. 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.
5. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
ProCarManuals.com
Page 191 of 457
4-44
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the front fork legs
Front wheel
Front brake calipers
Side cowlings
Front fender
Cap bolt
Handlebar pinch bolt
Upper bracket pinch bolt
Under bracket pinch bolt
Front fork leg1
1
1
1
2
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “COWLINGS” in chapter3.
Loosen.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
6 Nm (0.6 mkg, 4.3 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
17 Nm (1.7 mkg, 12 ftlb)
26 Nm (2.6 mkg, 19 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
FRONT FORKCHAS
EAS00647
FRONT FORK
FRONT FORK LEGS
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Page 194 of 457
4-47
FRONT FORKCHAS
WARNING
NOTE:
WARNING
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove
front wheel
front brake caliper
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
3. Remove:
Side Cowlings
Refer to “COWLINGS” in chapter 3.
handlebar
4. Loosen:
handlebar pinch bolt
1
upper bracket pinch bolt 2
cap bolt 3
under bracket pinch bolt 4
Before loosening the upper and under
bracket pinch bolts, support the front fork
leg.
5. Remove:
front fork leg
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Page 202 of 457
4-55
FRONT FORKCHAS
NOTE:
23 Nm (2.3 mkg, 17 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
17 Nm (1.7 mkg, 12 ftlb)
26 Nm (2.6 mkg, 19 ftlb)
WARNING
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
Make sure the inner fork tube is flush with the
top of the handlebar holder.
2. Tighten:
under bracket pinch bolt
1
cap bolt 2
handlebar pinch bolt 3
upper bracket pinch bolt 4
Make sure the brake hoses are routed prop-
erly.
3. Adjust:
spring preload
rebound damping
compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
ProCarManuals.com
Page 203 of 457
4-56
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15Removing the handlebars
Front cowling and side cowling
Left grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right grip end
Throttle cable housing
Throttle cable
Throttle grip
Front brake light switch connector
Right handlebar switch
Clutch cable holder
Brake fluid reservoir tank
Brake master cylinder bracket1
1
2
1
1
1
1
1
2
1
2
1
1
1
1Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Disconnect.
Disconnect.
113 Nm (11.3 mkg, 82 ftlb)
17 Nm (1.7 mkg, 12 ftlb)
11 Nm (1.1 mkg, 8.0 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
23 Nm (2.3 mkg, 17 ftlb)3.8 Nm (0.38 mkg, 2.7 ftlb)
3.8 Nm (0.38 mkg, 2.7 ftlb)
3.8 Nm (0.38 mkg, 2.7 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
26 Nm (2.6 mkg, 19 ftlb)
17 Nm (1.7 mkg, 12 ftlb)
HANDLEBARSCHAS
EAS00665
HANDLEBARS
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