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Brakes, wheels and tyres
8 . 3
11 Check the level of fluid in the hydraulic
reservoir and top-up if necessary (see Daily
(pre-ride) checks).
12 Check the operation of the brake before
riding the machine.
3 Front brake calipc
%
inspecti01
8
Ilation
Note: Caliper rebuild kits are not available for
the models covered. If the caliper is leaking
fluid from the piston seal area i t must be
3.la Undo the mounting bolts..
.
3.1 b
. . .
and remove the caliper
renewed.
Warning: If a caliper indicates the
need for renewal (usually due to
leaking fluid or sticky operation),
all old brake fluid should be flushed from
the system at the same time. Also, the dust
created by the brake system may contain
asbestos, which is harmful to your health.
Never blow
it
out with compressed air and
don't inhale any of
it.
An approved filtering
mask should be worn when working on the
brakes. Do not, under any circumstances,
use petroleum-based solvents to clean
brake parts. Use a dedicated brake cleaner
or denatured alcohol only, as described. To
prevent damage from spilled brake fluid,
always cover paintwork when working on
the braking system.
Note: On Speedfight models, the front wheel
must be removed before the caliper can be
removed (see Section 14).
Removal
1 Unscrew the brake caliper mounting bolts
and slide the caliper off the disc (see
illustrations). Note: Do not operate the brake
lever while the caliper is off the disc.
2 If the caliper is just being displaced, the
brake pads can be left in place. Support the
caliper with a cable tie to ensure no strain is
placed on the hydraulic hose.
3 If the caliper is being cleaned and
inspected, remove the brake pads (see
Section 2). Note: I t is not necessary to
disconnect the brake hose to clean and
inspect the caliper. Do not disconnect the
brake hose from the caliper unless the caliper
is being removed from the machine.
4 To remove the caliper from the machine,
first note the alignment of the banjo fitting on
the caliper, then unscrew the banjo bolt and
separate the hose from the caliper (see
illustration). Plug the hose end or wrap a
plastic bag tightly around it to minimise fluid
loss and prevent dirt entering the system.
Discard the sealing washers as new ones
must be used on installation.
Inspection
5 Clean the exterior of the caliper with
denatured alcohol or brake system cleaner.
Inspect the caliper for signs of damage,
especially around the mounting lugs and the
bleed screw and renew it if necessary. If
3.4 Unscrew the bolt to detach the hose
3.5 Fluid leaks indicate a failed seal
hydraulic fluid is leaking from around the edge
on removal. Tighten the banjo bolt securely
of the piston, the internal piston seal has
and top-up the hydraulic reservoir with DOT 4
failed (see illustration). Peugeot do not list
brake fluid (see Daily (pre-ride) checks). Bleed
caliper rebuild kits for the models covered and
the hydraulic system (see Section 8).
the caliper will have to be renewed -overhaul
9 Check for fluid leaks and check the
is not possible.
operation of the brake before riding the
lnstallation
6 If the brake pads have been removed,
install the pads (see Section 2).
7 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 (see illustration 3.1a). Operate the
brake lever several times to bring the pads
into contact with the disc.
8 If the caliper was removed from the
machine, or a new caliper is being fitted,
connect the brake hose to the caliper, using
new sealing washers on each side of the
banjo fitting. Align the banjo fitting as noted
4.2 Measuring the thickness of a disc with
a micrometer
machine.
Front b
inspecti
and ins!
lrake disc
ion, remo\
tallation
Note: Always renew the brake pads if fitting a
new disc.
1 Visually inspect the surface of the disc for
score marks and other damage. Light
scratches are normal after use and won't
affect brake operation, but deep grooves and
heavy score marks will reduce braking
efficiency and accelerate pad wear. If a disc is
badly scored it must be machined or
renewed.
2 The disc must not be machined or allowed
to wear down to a thickness less than the
service limit as listed in this Chapter's
Specifications. Check the thickness of the
disc with a micrometer and renew it if
necessary (see illustration).
3 To check disc warpage, position the
machine upright so that the wheel is raised off
the ground. Attach a dial gauge to the
suspension with the tip of the gauge touching
the surface of the disc about 10 mm from the
outer edge. Rotate the wheel and watch the
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