Page 164 of 457
4-17
FRONT AND REAR BRAKESCHAS
CAUTION:
WARNING
EAS00579
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Flush with water for 15 minutes and get im-
mediate medical attention.
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Page 166 of 457
4-19
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
35 Nm (3.5 mkg, 25 ftlb)
5. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose
1 tightly to the
bleed screw
2. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 mkg, 3.6 ftlb)
d. Install a new brake pad shim onto each new
brake pad.
Install the brake pad spring pointing
a toward
the bleed screw.
e. Install new brake pads and a new brake pad
spring.
6. Install:
brake pad pins
brake pad clips
brake caliper
7. 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.
8. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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Page 168 of 457
4-21
FRONT AND REAR BRAKESCHAS
27 Nm (2.7 mkg, 20 ftlb)
22 Nm (2.2 mkg, 16 ftlb)
a. Connect a clear plastic hose 1 tightly to the
bleed screw
2. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 mkg, 3.6 ftlb)
d. Install a new brake pad shim
3 onto each
new brake pad
4.
5. Install:
rear brake caliper (front)
rear brake caliper (rear)
brake pad pin
screw plug
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 pedal operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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Page 169 of 457
4-22
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the front brake master
cylinder
Brake fluid
Stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Brake lever
Front brake switch connector
Union bolt1
1
1
1
1
1
1
2
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
Disconnect.
3.8 Nm (0.38 mkg, 2.7 ftlb)
1.2 Nm (0.12 mkg, 0.9 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
30 Nm (3.0 mkg, 22 ftlb)
EAS00584
FRONT BRAKE MASTER CYLINDER
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Page 172 of 457
4-25
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the rear brake master
cylinder
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose joint
Bush
Union bolt
Copper washer
Brake hose
Brake master cylinder1
1
1
1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 mkg, 22 ftlb)18 Nm (1.8 mkg, 13 ftlb)
EAS00586
REAR BRAKE MASTER CYLINDER
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Page 174 of 457
4-27
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:
brake light switch connector
1
(from the brake light switch)
2. Remove:
union bolt
2
copper washers 3
brake hose 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove :
brake master cylinder bracket
brake master cylinder assembly
4. Remove :
dust boot
circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
union bolt
1
copper washers 2
brake hose 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
2. Remove :
brake master cylinder assembly
3. Remove :
dust boot
circlip
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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”.
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