BRAKES 12-11

Calipers

Front Caliper Removal

•Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

•Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

CAUTION

Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal. Loosening the caliper assembly bolts will cause brake fluid leakage.

•Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter).

Rear Caliper Removal

•Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

•Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

•Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter).

12-12 BRAKES

Calipers

Caliper Installation

•Install the caliper and brake hose lower end.

○Replace the washers on each side of hose fitting with new ones.

•Tighten:

Torque - Caliper Mounting Bolts:

Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)

Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Check the fluid level in the brake reservoirs.

•Bleed the brake line (see Brake Line Bleeding).

•Check the brake for good braking power, no brake drag, and no fluid leakage.

WARNING

Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first application of the lever or pedal if this is not done.

Front Caliper Disassembly

•Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Front Caliper Assembly

•Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Disassembly

•Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Assembly

•Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

BRAKES 12-13

Calipers

Caliper Fluid Seal Damage Inspection

The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.

•Replace the fluid seal if it exhibits any of the conditions listed below.

○Brake fluid leakage around the pad. ○Brakes overheat.

○Considerable difference in inner and outer pad wear. ○Seal and piston are stuck together.

If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed.

Caliper Dust Seal Damage Inspection

•Check that the dust seals [A] are not cracked, worn, swollen, or otherwise damaged.

If they show any damage, replace the dust seals with new ones.

Pistons [B] Fluid Seals [C]

Rear Caliper Dust Boot and Friction Boot Damage

Inspection

•Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged.

If they show any damage, replace it.

12-14 BRAKES

Calipers

Caliper Piston and Cylinder Damage Inspection

•Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty.

Rear Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.

•Check to see that the caliper holder shafts are not badly worn or stepped, and that the friction boot [B] is not damaged.

If the friction boot is damaged, replace the friction boot. To replace the friction boot, remove the pads and the caliper holder.

If the caliper holder shaft is damage, replace the caliper holder.