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8.2 Brakes, wheels and tyres
2.2a Brake pad retaining pins (arrowed)
2.2b Withdraw the pins..
.
2 . 2 ~
. .
.
and lift out the pads
Genera
The front brake on all models is a single,
hydraulically operated disc. The front brake
master cylinder is integral with the brake lever
and fluid reservoir on the right handlebar.
The rear brake is either an hydraulically
operated disc or a cable operated single
leading shoe drum. The rear disc brake
master cylinder and fluid reservoir assembly is
mounted on the left handlebar.
All models covered in this manual are fitted
with cast alloy wheels designed for tubeless
tyres only.
Caution: Disc brake components rarely
require disassembly. Do not disassemble
components unless absolutely necessary. If
an hydraulic brake hose is loosened, the
2.3 m . , , , , , ,
,
the amount of friction
material on each pad
entire system must be disassembled,
drained, cleaned and then pmpedy filled and
bled upon reassembly. Do not use solvents
on internal brake components. Solvents will
cause the seals to swell and distort Use only
clean brake fluid, a dedicated brake cleaner
or denatured alcohol for cleaning. Use care
when working with brake fluid as
it
can
injure your eyes and i t will damage painted
surfaces and plastic parts.
ont brakt
newal
?
pads
-
A
Warning: The dust created by the
brake
system
may
contain
asbestos, which is hannful to your
health. Never blow
it
out with compressed
air and don't inhale any of
it.
An approved
2.9a Ensure the pads are correctly
installed
. . .
2.9b
. . .
and ensure the pins lock in the
back of the caliper
filtering mask should be worn when
working on the brakes.
1 Unscrew the brake caliper mounting bolts
and slide the caliper off the disc
(see
Section 3).
Note: Do not operate the brake lever while the
caliper is off the disc.
2 The pads are retained in the caliper by two
spring wire pins (see illustration). Withdraw
the pins, noting how they fit, then lift the pads
out of the caliper (see illustrations).
3 lnspect the surface of each pad for
contamination and check that the friction
material has not worn to or beyond the
minimum thickness specified at the beginning
of this Chapter (see illustration). If either pad
is worn down to, or beyond, the service limit,
is fouled with oil or grease, or heavily scored
or damaged, both pads must be renewed.
Note: It is not possible to degrease the friction
material; if the pads are contaminated in any
way they must be renewed.
4 If the pads are in good condition, clean
them carefully using a fine wire brush which is
completely free of oil and grease to remove all
traces of road dirt and corrosion. Spray the
caliper with a dedicated brake cleaner to
remove any dust and remove any traces of
corrosion which might cause sticking of the
caliper/pad operation.
5 Check the condition of the brake disc (see
Section 4).
6 Remove all traces of corrosion from the pad
pins. lnspect the pins for damage and loss of
spring tension and renew them if necessary.
7 If new pads are being installed, slowly push
the pistons as far back into the caliper as
possible using hand pressure or a piece of
wood for leverage. This will displace brake
fluid back into the hydraulic reservoir, so it
may be necessary to remove the reservoir
cap, plate and diaphragm and siphon out
some fluid (depending on how much fluid was
in there in the first place and how far the
pistons have to be pushed in). If the pistons
are difficult to push back, attach a length of
clear hose to the bleed valve and place the
open end in a suitable container, then open
the valve and try again. Take great care not to
draw any air into the system and don't forget
to tighten the valve once the pistons have
been sufficiently displaced. If in doubt, bleed
the brakes afterwards (see Section 8).
Caution: Never lever the caliper against the
brake disc to push the pistons back into the
caliper as damage to the disc will result.
8 Smear the backs of the pads with copper-
based grease, making sure that none gets on
the front or sides of the pads.
9 Installation is the reverse of removal. Fit the
pads into the caliper so that the friction
material faces the disc, then install the pad
pins and check that they lock in the recesses
at the back of the caliper (see illustrations).
10 Install the caliper onto the disc ensuring
the pads fit over each side of the disc, then
tighten the caliper bolts to the specified
torque. Operate the brake lever several times
to bring the pads into contact with the disc.
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