FRONT BRAKE

Removing the front brake caliper

Order

Job/Parts to remove

Q’ty

Remarks

 

Brake fluid

 

Drain.

Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM.

1

Union bolt

1

 

2

Copper washer

2

 

3

Front brake hose

1

 

4

Brake pad pin plug

1

 

5

Brake pad pin

1

 

6

Brake pad

2

 

7

Brake pad spring

1

 

8

Front brake caliper assembly

1

 

9

Front brake caliper bracket

1

 

10

Brake pad spring

1

 

Disassembling the front brake caliper

Order

Job/Parts to remove

Q’ty

Remarks

1

Brake caliper piston

2

 

2

Brake caliper piston dust seal

2

 

3

Brake caliper piston seal

2

 

4

Bleed screw

1

 

Removing the front brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

 

Brake fluid

 

Drain.

Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM.

1

Brake lever

1

 

2

Union bolt

1

 

3

Copper washer

2

 

4

Front brake hose

1

 

5

Brake master cylinder reservoir cap

1

Adjust the front brake master cylinder so that the top “a” of the brake master cylinder reservoir cap is horizontal.

6

Brake master cylinder reservoir diaphragm

1

 

7

Front brake master cylinder float

1

 

8

Front brake master cylinder holder

1

 

9

Front brake master cylinder

1

 

Disassembling the front brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

1

Brake master cylinder kit

1

 

INTRODUCTION

If you need to disassemble the disc brake components, observe the following precautions.

  • Never disassemble the brake components unless absolutely necessary.

  • If there is any problem with connections on the hydraulic brake system, perform the following jobs. Disassemble the brake system, drain the brake fluid, and clean it. After that, add a suitable amount of brake fluid. Then, bleed it after reassembly.

  • Use only brake fluid for washing brake components.

  • Use new brake fluid for cleaning the brake components.

  • Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or plastic parts.

  • Handle brake fluid with special care not to let it enter your eyes so that you may not lost your eyesight.

  • FIRST AID FOR BRAKE FLUID ENTERING THE EYES:

  • Flush with water for 15 minutes and get immediate medical attention.

CHECKING THE FRONT BRAKE DISC

1.Check:

  • Front brake disc

    Damage/galling → Replace.

2.Measure:

  • Brake disc thickness

    Measure the brake disc thickness at a few different locations.

    Out of specification → Replace.

  • Brake disc thickness limit

    2.5 mm (0.10 in)

3.Measure:

  • Brake disc runout

    Out of specification → Replace the brake disc.

  • Brake disc runout limit (as measured on wheel)

    0.15 mm (0.0059 in)

a.Place the vehicle on a maintenance stand so that the front wheel is elevated.

b.Remove the brake caliper.

c.Hold the dial gauge at a right angle against the brake disc surface.

d.Measure the runout 1.5 mm (0.06 in) above the brake disc edge.

4.Replace:

REPLACING THE FRONT BRAKE PADS

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.

1.Remove:

  • Brake pad

a.Remove the pad pin plug “1”.

b.Loosen the pad pin “2”.

c.Remove the brake caliper “3” from the front fork.

d.Remove the pad pin and brake pads “4”.

2.Measure:

  • Brake pad wear limit “a”

    Out of specification → Replace the brake pads as a set.

  • Brake pad lining thickness limit

    1.0 mm (0.04 in)

3.Install:

  • Brake pad

a.Connect the plastic hose “1” to the bleed screw “2” and place a container under the end of the plastic hose.

b.Loosen the bleed screw and push the brake caliper piston in.

Do not reuse the drained brake fluid.

c.Tighten the bleed screw.

  • Bleed screw

    5 N·m (0.5 kgf·m, 3.7 lb·ft)

d.Install the brake pads “3” and the pad pin.

  • Install the brake pads with their projections “a” into the brake caliper recesses “b”.

  • Temporarily tighten the pad pin at this point.

e.Install the brake caliper “4” and tighten the pad pin “5”.

  • Front brake caliper bolt

    28 N·m (2.8 kgf·m, 21 lb·ft)

  • Pad pin

    17 N·m (1.7 kgf·m, 13 lb·ft)

f.Install the pad pin plug “6”.

  • Pad pin plug

    2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

4.Check:

5.Check:

REMOVING THE FRONT BRAKE CALIPER

Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

1.Remove:

  • Union bolt

  • Copper washer

  • Brake hose

Put the end of the brake hose into a container and pump out the brake fluid.

DISASSEMBLING THE FRONT BRAKE CALIPER

1.Remove:

  • Brake caliper piston “1”

  • Brake caliper piston dust seal “2”

  • Brake caliper piston seal “3”

a.Blow compressed air into the brake hose joint opening 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 piston is expelled from the brake caliper.

  • Never try to pry out the brake caliper piston.

b.Remove the brake caliper piston dust seal and the brake caliper piston seal.

CHECKING THE FRONT BRAKE CALIPER

1.Check:

  • Brake caliper piston “1”

    Rust/scratches/wear → Replace the brake caliper piston.

  • Brake caliper cylinder “2”

    Scratches/wear → Replace the brake caliper assembly.

  • Brake caliper body “3”

    Cracks/damage → Replace the brake caliper assembly.

  • Brake fluid delivery passages

    (brake caliper body)

    Obstruction → Blow out with compressed air.

When the brake caliper is disassembled, replace the brake caliper piston seal and the brake caliper piston dust seal with new ones.

2.Check:

  • Brake caliper bracket

    Crack/damage → Replace.

ASSEMBLING THE FRONT BRAKE CALIPER

  • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating.

  • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.

  • When the brake caliper is disassembled, replace the brake caliper piston seal and the brake caliper piston dust seal with new ones.

  • Specified brake fluid

    DOT 4

INSTALLING THE FRONT BRAKE CALIPER

1.Install:

  • Front brake caliper bracket

  • Front brake caliper

    (temporarily)

  • Copper washer

  • Brake hose

  • Union bolt

  • Front brake caliper bracket

    28 N·m (2.8 kgf·m, 21 lb·ft)

  • Brake hose union bolt

    30 N·m (3.0 kgf·m, 22 lb·ft)

Proper brake hose routing is essential to insure safe vehicle operation.

Make sure that the pipe portion “a” of the brake hose touches the projection “b” on the brake caliper.

2.Install:

  • Front brake caliper

  • Brake pad spring

  • Brake pad

  • Brake pad pin

  • Brake pad pin plug

  • Plate

  • Brake pad pin

    17 N·m (1.7 kgf·m, 13 lb·ft)

  • Brake pad pin plug

    2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

Refer to CHECKING THE FRONT BRAKE PADS.

3.Tighten:

  • Plate bolt “1”

  • Plate bolt

    3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

Make sure that the plate “2” is installed with its upper end “a” aligned with the paint “b” on the brake hose.

4.Pour brake fluid to the brake master cylinder reservoir up to the specified level.

  • Specified 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 performance.

  • 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:

6.Check:

7.Check:

REMOVING THE FRONT BRAKE MASTER CYLINDER

Before removing the front brake master cylinder, drain the brake fluid from the entire brake system.

1.Remove:

  • Union bolt

  • Copper washer

  • Brake hose

To drain any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

CHECKING THE FRONT BRAKE MASTER CYLINDER

1.Check:

  • Brake master cylinder “1”

    Damage/scratches/wear → Replace the brake master cylinder assembly.

  • Brake fluid delivery passages “2”

    (brake master cylinder body)

    Obstruction → Blow out with compressed air.

2.Check:

  • Brake master cylinder reservoir cap

    Damage/scratches/wear → Replace.

3.Check:

  • Brake hose

    Cracks/damage/wear → Replace.

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER

  • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.

  • Never use solvents on internal brake components.

  • Specified brake fluid

    DOT 4

1.Wash the brake master cylinder with brake fluid.

2.Install:

  • Primary cylinder cup “1”

  • Secondary cylinder cup “2”

    (to the brake master cylinder piston “3”)

Apply brake fluid to the cylinder cups and install them as shown. Wrong orientation in installation causes poor braking performance.

3.Install:

  • Spring “1”

    (to the brake master cylinder piston “2”)

Install the spring with a smaller inside diameter to the brake master cylinder piston.

4.Install:

  • Brake master cylinder piston assembly “1”

  • Washer “2”

  • Circlip “3”

  • Dust boot “4”

  • Push rod “5”

  • Before installation, apply brake fluid to the components of the brake master cylinder piston assembly.

  • Before installation, apply silicone grease to the push rod end.

  • Before installation, apply brake fluid to the inside of the brake master cylinder.

INSTALLING THE FRONT BRAKE MASTER CYLINDER

1.Install:

  • Brake master cylinder “1”

  • Brake master cylinder holder bolt

    9 N·m (0.9 kgf·m, 6.6 lb·ft)

  • Install the front brake master cylinder holder with the “UP” mark facing up.

  • First, tighten the upper bolt, then the lower bolt.

2.Install:

  • Copper washer

  • Brake hose

  • Union bolt

  • Brake hose union bolt

    30 N·m (3.0 kgf·m, 22 lb·ft)

Proper brake hose routing is essential to insure safe vehicle operation.

During installation, bring the brake hose into contact with the brake master cylinder projection “a” and make its bent portion “b” face downward.

Turn the handlebar toward right and left to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Adjust if necessary.

3.Pour brake fluid to the brake master cylinder reservoir up to the specified level.

  • Specified 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 performance.

  • 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:

5.Check:

6.Check: