hydraulic brake front:

8/14/2019 Hydraulic Brake Front:

1/31

HYDRAULIC BRAKE

FRONT:

34 N-m

30 N*m (3.1 kgf-m, 22 Ibf-ft)

15-0


2/31

15. HYDRAULIC BRAKE

15-17

15-3 FRONT BRAKE CALIPER 15-21

REAR BRAKE CALIPER 15-25

AIR BLEEDING 15-4 BRAKE PEDAL 15-28

BRAKE PAD/DISC 15-8FRONT MASTER CYLINDER 15-12

SERVICE INFORMATION 15-2 REAR MASTER CYLINDER

TROUBLESHOOTING

BRAKE FLUID REPLACEMENT/

EAR:

25 Ibf-ft)

22 N*m (2.2kgf-m, 16 Ibf-ft)

15-1


3/31

HYDRAULIC BRAKE

Brake disc thickness

SERVICE INFORMATION

4.5 (0.18) 3.5 (0.14)

GENERAL

Brake disc r unou t

Frequent inhalation of brake pad dust, regardless of material com posi tion c ould be hazardous to yo ur health.Avoi d breathing dust particles.

Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

0.30 (0.012)

A conta minated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc wita hig h quality brake degreasing agent.Check the brake system by app lyin g the brake lever or pedal after the air bleeding .

Spilled brake fluid will severely damage in strument lenses and pain ted surfaces. It is also harmful to some rub ber parts. B

careful whenever yo u r emov e the reservoir cap; make sure the fron t reservoir is horizo ntal first.Never allow contaminates (dirt, water, etc.) to get int o an open reservoir.Once the hydraulic system has been opened, or if the brake feels spongy, the sys tem m ust be bled.

Alwa ys use fresh DOT 4 brake flui d fro m a sealed container when servicing the system. Do not m ix different types o f flui

they m ay no t be compatible.Alwa ys check brake operation before ridi ng the motorcycle.

Master cylinder I.D.

Master piston O.D.

FlCAT1ONS

17.460 - 17.503 (0.6874- 0.6891)17.321 - 17.367 (0.6819 - 0.6837)

17.515 (0.6896)

17.309 (0.6815)

Unit: mm ( in

Caliper cyli nder I.D.

Front

Uppe r (Cylinder A)

Lowe r (Cylinder 6 )32.025 - 32.035 (1.2608- 1.2612)

30.250 - 30.280 (1.1909 - 1.1921)

32.05 (1.262)

30.29 (1.193)

Rear

Caliper piston O.D.

ITEM 1 STANDARD 1 SERVICE LIMIT

Upper (Piston A)

Lower (Piston B)31.965

-

31.998 (1.2585-

1.2598)

30.082 - 30.1 15 (1.1843- 1.1856)

31.953 (12580)30.074 (1.1840)

~ ~~

Specified brake flui d

Specified brake flui d

Brake disc thickness

-Honda DOT 4 Brake Fluid I

+-4.0 (0.16)Honda DOT 4 Brake Fluid5.0 (0.20)Master cylinder I.D.

Master p iston O.D.

15.870 - 15.913 (0.6248 - 0.6265)15.827 - 15.854 (0.6231 - 0.6242)

15.925 (0.6270)

15.815 (0.6226)

Caliper cylinder I.D. 38.180 - 38.230 (1.5031- 1.5051) 38.24 (1.506)

Caliper cylinder O.D. 1 38.098 -38.148 (1.4999 - 1.5019)

Brake disc runou t - 1 0.30 (0.012)I38.090 (1.4996)

15-2


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5/31

HYDRAULIC BRAKE

BRAKE FLUID REPLACEMENT/AIRNG

Do not allow foreign material to enter the system

when filling the reservoir,

Avoid spilling fluid on painted, plastic, or rubber

parts. Place a rag over these parts whenever thesystem isserviced.

BRAKE FLUID DRAiNlNGFor the front brake, turn the handlebar until the reser-

voir is parallel to the ground, before removing the

reservoir cap.

Loosen the master cylinder reservoir mounting nut.Remove the screws and reservoir cap.

Remove the diaphra gm plate, diaphra gm and float.

For the rear brake, remove the rear brake reservoir

mounting bolt.

Remove the reservoir cap.

\

NUT

n

Remove the diaphragm plate and diaphragm.


6/31

HYDRAULIC BRAKE

Connect a bleed hose to the caliper bleed valve.

BRAKE FLUID FILLING/AIR BLEEDING

Loosen the bleed valve a nd pu mp the brake lever or

pedal.

Stop pump ing the lever or pedal when no more f luid

flo ws ou t of the bleed valve.

UPPER,LEVELFi l l the reservoir wit h DOT 4 brake flui d fro m a sealed

container.

NOTE:

Use only DOT 4 brake fluid fr om a sealed container.Do not mix different types of fluid. They are not

compatible.

45-5


7/31

HYDRAULIC BRAKE

Connect a commercially available brake bleeder to the

bleed valve.

Operate the brake bleeder and l oosen the bl eed valve.

If an automatic refill system is not used, add fluidwhe n the fluid level in the reservoir is low.Perform the bleeding procedure until the system iscompletely f lushed/b led.Close the bleed valve and operate the brake lever o rpedal. If it stil l feels spongy, bleed the system again.

If the brake bleeder is no t available, p erf orm the fol-

low ing procedure.

Pressurize the system with the lever or pedal until

there are no air bubbles in the f luid f lowing out of the

reservoir small hole and lever resistance is felt.

5-6


8/31


9/31

HYDRAULIC BRAKE

On the fro nt brake, install the reservoir cap, a nd tight -

en th e screws.

Tighten the master cylinder reservoir mounting nut

securely.

IR CAP

On the rear brake, install the reservoir cap securely,

then install the reservoir onto t he frame and tighten

the mounting bolt.

KE PAD/DISCAiways repiace FRONT BRAKE PAD REPLACEMENT

the brake pads inPairs to assureeven d i s c p r e s -

sure

Loosen th e pad pins.

Remove the bolts and brake caliper.

Check t!Je biakef luid /eve/ inThe

brake masteryiinder reservoiras this opeiationcauses the/eve/

to rise

Puslation of new brake pads.

the caliper pistons al l the way in I allow instal-

\

NUT

'I5-8


10/31

HYDRAULIC BRAKE

ecarefulno t tomage the pads.

Remove the I3ad pins, pad spring and brake pads.

Clean the inside of the caliper especially aroun d the

caliper pistons.

Install the new brake pads.

Install the pad spring with its arrow mark facing up

(page 15-23).

Push the p ad spring, th en install the pad pin.

Install the brake caliper to the fork leg so the disc ispositioned between the pads.

Install and tighten the new brake caliper mounting

bolts.

TORQUE: 30 N-m (3.1 kgf-m, 22 Ibf-ft)Tighten the pad pins.

TORQUE: 18 N-m (1.8 kgf-m, 13 Ibf-ft)


11/31

HYDRAULIC BRAKE

Aiways repiacethe brake pads in

pairs to assureeven disc PeS-sure

REAR BRAKE PAD REPLACEMENT

Check the brake fluid level in the brake master cylin-der reservoir as this operatio n causes the level to rise.

Push the caliper pistons all the way in b y pushing the

caliper bo dy inwa rd to al low installation of new brakepads.

Remove the pad pin plug.

Loosen the pad pin .

Remove the caliper mounting bolt.

Pivot the caliper up.

Remove the pad p in and brake pads.


12/31

HYDRAULIC BRAKE

Make sure the brake pad spr ing i s in place.Install the new brake Dads.

Lower the caliper while pushing the pads against thepad spring so the pad ends are positioned onto theretainer on the caliper bracket.

Install the pad pin.

Install and tighten the caliper m ounti ng bolt.

TORQUE: 22 N-m (2.2 kgf-m, 16 Ibf-ft)Tighten the pad pin.

TORQUE: 18 N- m (1.8 kgf-m, 13 Ibf-ft)

Install and tighten the pad pi n plug.

TORQUE: 2 N-m (0.25 kgf-m, 1.8 Ibf-ft)

BRAKE DISC INSPECTION

Visually inspect the brake disc for damage or crack.

Measure the brake disc thickness with a micrometer.

SERVICE LIMITS:

FRONT: 3.5 mm (0.14 in )

REAR: 4.0 mm (0.16 in )

Replace the brake disc if the smallest measuremen t isless than the service limit.

15-11


13/31

HYDRAULIC BRAKE

Measure the brake disc warpage w it h a dial indicator.

SERVICE LIMIT: 0.30 mm (0.012 in)

Check the wheel bearings for excessive play, if the

warpage exceeds the service limit.Replace the brake disc if the wheel bearings are nor -

mal.

MASTER CYLINDER

REMOVAL

Drain the fro nt hydraulic system (page 15-4).void spiihng fiuid

~ Jpainted, plas-tic, or rubberarts Piace a ragover these parts

whenever the

systein isser-viced

Disconnect the brake lig ht switch wire connectors.

Remove the brake hose oil bolt, sealing washers and

brake hose eyelet.

Remove the bolts from th e master cylinder holder a nd

remove the master cylinder assembly.MASTER CYLINDER

DISASSEMBLYRemove the dust cover and snap ring.

TOOL:

Snap ring pliers 07914-SA50000Remove the bolt and brake reservoir fro m the master

cylinder.

Remove the O-ring.

2


14/31

HYDRAULIC BRAKE

Remove the pivot b o l t h u t and brake lever assembly. PIVOT BOLT

Remove the screw and brake ligh t switch.

Remove the b oot.

BRAKE 'LEVER PIVOT NUT

SCREW BRAKE LIGHT SWITCH\ /

Remove the snap r ing from the master cylinder bod yusing the special tool as shown.

SNAP RING/TOOL:Snap ring pliers 07914-SA50000

Remove the master piston and spring.

Clean the inside of the cylinder and reservoir withbrake fluid.

15-13


15/31

HYDRAULIC BRAKE

INSPECTION

Check the piston boot, primary cup and secondarycup for fatigue or damage.

Check the master cylinder and piston for abnormal

scratches.Measure the master cyl inder I.D.


Measure the master cylinder piston O.D.


ASSEMBLYRESERVOlR

DIAPHRAGM

DIAPHRAGM

SNAP RING

MASTER CYLINDER

BRAKE LIGHT SWITCH

6N-m (0.6 kgf-m, 4.3 Ibf-ft)


16/31

HYDRAULIC BRAKE

Keep thepisron, Coat all parts wi th clean brake fluid before assembly. MASTER CYLINDER SPRINGcups, spring, snap \ring andbootasaset do nots u m t i -

tuteindiv/duaipartsWheninstaiiing

thecups, dono taiiow the /IPS toturn[nside ou t

Dip the piston i n brake fluid.

Install the spring into the piston.

Install the piston assembly into the master cylinder.

5 e cer ta in thesnap ring is firmly

Install the snap r ing.

seated in the TOOL:groove Snap ring pliers

Install the boot.

SNAP RING/

Install the brake light switch and tighten the screw to SCREW BRAKE LIGHT SWITCH

the specified torque. \ /

15-15


17/31

YDRAULIC BRAKE

A&Apply silicone grease to the contact surfaces of thebrake lever and pist on tip. /\

Install the brake lever assembly, tighten the p ivo t bol t

t o the specified torque.

TORQUE: 10 N-m (1.0 kgf-m, 7 Ibf-ft)Hold the pivot bolt and tighten the pivot nut to the

specified torque.

TORQUE: 6 N-m (0.6 kgf-m, 4.3 Ibf-ft)

Apply brake fluid to the new reservoir joint O-ring.

Install the master cylinder reservoir join t into the mas-

ter cylinder and secure the joint wit h a snap ring.

TOOL:Snap ring pliers 07914-SA50000

Install the dust cover.Install and tighten the reservoir m ount ing bolt.

PIVOT BOLT

BRAKE'LEVER PIGOT NUT

BOLT


18/31

HYDRAULIC BRAKE

Place the master cylinder assembly on the handlebar.

Align the end of the master cylinder with the punch

mark on the handlebar.

Install the master cylinder holder with the UP mark

facing up.

Tighten the upper bolt first, then the lowe r bolt.

Install the brake hose eyelet with the oil bolt and new

sealing washers.

Push the eyelet join t against the stopper, then tighte n

the oil bolt to th e specified torque.

TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)Connect the brake lig ht switch wire connectors.

Fill the reservoir to the upper level and bleed the

brake system (page 15-5).

REAR MASTER CYLINDER

REMOVALDrain the rear hydraulic system (page 15-4).

Remove the rear master cylinder reservoir mou ntin g

bolt.

Avoid spiiiing fluidonpainted, P/aSfiC, brake hose.

or rubber parts

lace a ra g Overhese parts when-

ever thesystemis serviced

Caiifornia typeoniy

Remove the brake hose oil bolt, sealing washers and

Loosen the rear master cylinder mounting bolts.

Remove the main footpeg bracket socket bolts and

mai n foot peg bracket assembly.

Release the 0 2 sensor wire from the wire guide

behind the ri ght step guard.


19/31

YDRAULIC BRAKE

Remove and discard the brake pedal joint cotter pin.

Remove the joint pin.

Remove the master cylinder mounting bolts, collars

(California type only), step guard and master cylinder.

DISASSEMBLY

Remove the screw and reservoir hose joint from the

master cylinder.

Remove the boot.

Remove the snap r ing from the master cylinder body

using the special tool as shown.

TOOL:Snap ring pliers 07914-SA50000

RESERVOIR JOINT/

SNAP RING PLIERS BOOT

Remove the push roc, master piston and spring.

Clean the inside of the cylinder wi th brake fluid .

5-18


20/31

HYDRAULIC BRAKE

INSPECTION

Check the piston boot, primary cup and secondarycup for fatigue or damage.

Check the master cylinder and piston for abnormalscratches.Measure the master cylinder I.D.


Measure the master cylin der pisto n O.D.



21/31

YDRAULIC BRAKE

Keepth e pistonups spring, snap

ng and boo?asa

et, donot substi-

tute individual

parts

Coat all parts with clean brake fluid before assembly.

Wheninstaii ing Dip the piston in brake fluid.theCUPS, do no? Install the spring to the primary cup.ai iow the /ips to Install the spr i ng ip r imary cup and master piston

Appl y silicone grease to the piston contact area of th epush rod.

turn insideO u t assembly .

f thepushrod is

disassembled,

efer to page 3-26

for push rod

length adjust-ment

Be certain thenap ringis f i rmiy

seatedin the TOOL:

Install the push rod into the master cylinder.

Install the snap ring.

groove Snap ring pliers 07914-SA50000Install the boot.

Apply a locking agent to the reservoir joint screw

threads.Install and tighten the screw to the specified torque.

TORQUE: 1 N-m (0.1 kgfom, 0.7 Ibf-ft)

PRlMPjRYCUP/ MASTER PISTON

)i. / ASSEMBLY

Apply brake fluid to a ne w - O-ring and install it onto

the reservoir joint.Install the reservoir joint into the master cylinder.

RESERVOIR JOINT/

15-20


22/31

HYDRAULIC BRAKE

INSTALLATION

Place the master cylinder onto the main footpeg

bracket, install the collars (California typ e onl y), stepguard and master cylinder m ounting bolts.

Connect the brake pedal to the push r od lo wer joint.Install the joint pin andsecure it wit h a ne w cotter pin.

Caiifcrnia type Clamp the 0 2 sensor wire to the wire guide behin d theoniy right step guard.

Install the main footpeg bracket onto the lower brack-

et, tighten the socket bolts to the specified torque.

TORQUE: 39 N- m (4.0 kgf-m, 29 Ibf-ft)Tighten the master cylinder mounti ng bolts.

Install the brake hose with the oil bolt and n ew seal-in g washers.

Push the eyelet joint against the stopper, then ti ghte n

the oil bolt to the specified torque.I

TORQUE: 34 N- m (3.5 kgf-m, 25 Ibf-ft)Install and tighten the brake reservoir mou nti ng bolt.

Fi l l the reservoir to the upper level and bleed thebrake system (pa ge 15-51,Adjust the brake pedal height (page 3-26).

FRONT BRAKE CALIPERREMOVAL

Drain the front brake hydraulic system (page 15 -4).

Remove the oil bolt, sealing washers and brake hose

Remove the caliper mounting bolts, caliper and thebrake pads (page 15-8).

iuidn painted, piastic, eyelet joint.

or rubberpartsPiace a rag O v e rhese parts when-

ever the systemis serviced

OIL BOLT/MOUNTI?G BOLTS

15-21


23/31

HYDRAULIC BRAKE

DISASSEMBLY

Install corrugated cardboard or equivalent between

the pistons.Apply small squirts of air pressure to th e fluid inlet to

remove the pistons.

Do not use high

pressure air orbnng rhe nozzletoo close to the

inlet

Mark the pistonstoensure correct

Remove the following:

- Joint sealsreassemb/y - Caliper pisto n A

- Caliper pisto n B

Bec a r e f d n o t tosliding surface

Push the dust seals and piston seals in and lift them

amage the piston out.

Clean the seal grooves w it h clean brake fluid .

15-22


24/31

HYDRAULIC BRAKE

INSPECTION

Check the caliper cylinder for scoring or other dam -

age.

Measure the caliper cylinder I.D.

SERVICE LIMITS:

Cylinder A (Upper): 32.05 mm (1.262 in)Cylinder B (Lower): 30.29 mm (1.193 in)

Check the caliper pistons for scratches, scoring or

other damage.

Measure the caliper piston O.D.

SERVICE LIMITS:

Piston A (Upper): 31.953 mm (1.2580 in)Piston B (Lower): 30.074 mm (1.1840 in)

ASSEMBLY

PISTON SEAL

CALIPER PISTON B

BRAKE PADS 23 N-m (2.3 kgf-m, 17 Ib fW

15-23


25/31

HYDRAULIC BRAKE

Coat the new piston seals wi th clean brake fluid.

Coat the new dust seals with silicone grease.

Install the pist on and dust seal in to the groove o f the

caliper body.

Coat the caliper pistons with clean brake fluid and

install the m into the caliper cylinder wit h their open

ends towar d the pad.

LIPERTON

Install the new joint seal i nto the fluid passage on the

caliper.

Assemble the caliper halves and install and tightenthe new caliper assembly torx bolts to the specified

torque.

TORQUE: 23 N-m (2.3 gf-m,7 IbfW

INSTALLATIONInstall the brake pads and caliper onto the fork leg

(page 15-9).

Install and tighten the new caliper mou nting bolts to

the specified torque.

TORQUE: 30 N-m(3.1 gf-m,22 Ibf-ft)Install the brake hose eyelet to the caliper bo dy wi th

tw o new sealing washers and oil bolt.

TORX BOLTS

15-24


26/31

HYDRAULIC BRAKE

Push the brake hose eyelet to the stopper on the

caliper, then tighten the oi l bolt to the specified

torque.

TORQUE:34 N-m (3.5 kgfsm, 25 Ibf-ft)Fill and bleed the front brake hydraulic system (page15-5).

EAR BRAKE CALIPER

REMOVAL

Drain the rear brake hydraulic system (page 15-4).

Remove the oil bolt, sealing washers and brake hoseoidspiiiing fiwdpainted, piastic, eyelet joint.or rubber parts

a rag over

se parts wh en-ver thesystem

is serviced

Remove the caliper bracket bolts and the brake pads

(page 15-10).

Pivot the caliper up and remove it.

DISASSEMBLY COLLAR BOOT

Remove the pad spring, collar and boot from thecaliper body.

PAD SPRING *

15-25


27/31

HYDRAULIC BRAKE

Do not use high

pressureair orbring the nozzletooclose to the

inlet

Place a shop to wel over the piston.

Position the caliper body with the piston down and

apply small squirts of air pressure to t he fluid inlet toremove the piston.

PISTON SEALBe careful not todamage the piston

sliding surfacePush the dust seal and piston seal in a nd lift them out.

Clean the seal grooves w it h clean brake fluid.

INSPECTIONCheck the caliper cylinde r for scoring or other damage.

Measure the caliper cylinder I.D.


Check the caliper pistons for scratches, scoring or

other damage.

Measure the caliper piston O.D.

SERVICE LIMIT: 38.090 mrn (1.4996 in)

15-26


28/31

HYDRAULIC BRAKE

ASSEMBLY

Coat the ne w piston seal with clean brake fluid.Coat the new dust seal wi th silicone grease.

Install the pi ston seal and dust seal int o the groove ofthe caliper body.

Coat the caliper piston with clean brake fluid andinstall it into the caliper cylinder wit h its opening endtowar d the pad.

Install the pad sprin g i nto the caliper body.If the caliper and bracket pin boots are hard or deteri-orated, replace them w ith new ones.

Apply silicone grease to the inside of the bracket pin

boot.install the bracket pin boot and collar int o the caliper.


29/31

YDRAULIC BRAKE

Install the pad retainer i nto the bracket.

INSTALLATION

Appl y silicone grease to the caliper pin and install thecaliper onto the bracket.

Install the rear brake pads (page 15-11).

Install and tighten the caliper mounting bolt to thespecified torque.

TORQUE: 22N-m(2.2 gf-m,16 Ibfoft)

Install the brake hose eyelet to the caliper body w ithtw o ne w sealing washers and oil bolt.Align the brake hose eyelet to the stopper on th ecaliper, then tighten the oil bolt to the specified

torque.

TORQUE: 34N.m (3.5 gf-m,25 Ibf-ftlFill and bleed the rear brake hydraulic system (page15-5).

BRAKE PEDAL

REMOVAL

C2/ / fo rn /atype Release the 0 2 sensor wire from the wire guideonly behind the r ight step guard.

Remove the main footpeg bracket moun ting bolts and

bracket assembly fr om t he lower bracket.

Remove and discard the brake pedal joint cotter pin.Remove the joint pin.

Unhook the return spring and remove the brake light

switch fr om the step holder.Unhook the brake pedal return spring.

Remove the footpeg mounting bolt, footpeg, brakepedal and wave washer.

1 0 2 SENSOR WIRE

~ RIGHT FOOTPEGBRACKET B0LTS

5-28


30/31

HYDRAULIC BRAKE

App ly grease to the sliding surface of the brake pedal

and footpeg.Assemble the brake pedal, footpeg and wave washer.

Install a new footpeg mo unting bolt and tighten i t to

the specified torque.

TORQUE: 44 N-m (4.5 kgfom, 33 Ib fWAttach the brake pedal return spring.Install the brake light switch and attach the switchspring.Connect the brake pedal to the push ro d low er joint.

Install the joint pin and secure it with a new cotter pi n.

15-29


31/31

HYDRAULIC BRAKE

Cabforrxa type Clamp the 0 2 sensor wire to the wir e guide behi nd theonly right step guard.

Install the right mai n footpeg bracket assembly o ntothe lowe r bracket.

Install and tighten the right main footpeg bracketsocket b olts to the specified torque.

TORQUE: 39 N-m (4.0kgf-m,29 bf-ft)

0 2 SENSOR WIRE

RIGHT FOOTPEG BRACKET BOLTS

hydraulic brake front:

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