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Brakes, wheels and tyres
8 . 5
6 . 2
Undo the screw and remove the
bracket
as for the front brake. Note: The rear wheel
must be removed before the caliper can be
removed (see Section 15).
2 Note the routing of the rear brake hose
before displacing the caliper, then undo the
screw securing the hose bracket to the
underside of the drive belt cover and remove
the bracket (see illustration).
3
The caliper is secured to the transmission
casing by two bolts (see illustration).
4 If the caliper is just being displaced, secure
it to the machine with a cable tie to avoid
straining the hose. Note: Do not operate the
brake lever while the caliper is off the disc.
5 After working on any component in the
brake system, always check the operation of
the brake before riding the machine.
7 Brake hose(s) and unions
-
inspection and renewal
Inspection
1 Brake hose condition should be checked
regularly and the hose(s) renewed at the
specified interval (see Chapter 1).
2 Remove the body panels as necessary (see
Chapter 7).
3
Twist and flex the hose while looking for
cracks, bulges and seeping fluid. Check extra
carefully around the areas where the hose
connects with the banjo fittings, as these are
common areas for hose failure.
4 Inspect the banjo fittings; if they are rusted,
cracked or damaged, fit a new hose.
Renewal
5 The brake hose(s) have banjo fittings on
each end. Cover the surrounding area with
plenty of rags and unscrew the banjo bolt at
each end of the hose, noting the alignment of
the fitting with the master cylinder or brake
caliper (see illustration). Free the hose from
any clips or guides and remove it, noting its
routing. Discard the sealing washers. Note:
Do not operate the brake lever while a brake
hose is disconnected.
6 Position the new hose, making sure it is not
twisted or otherwise strained, and ensure that
it is correctly routed through any clips or
6 . 3
Brake caliper is secured by two bolts
7.5 Note the alignment of the fitting (A)
before undoing the bolt (B)
guides and is clear of all moving components
(see illustration).
7 Check that the fittings align correctly, then
install the banjo bolts, using new sealing
washers on both sides of the fittings (see
illustration 5.4). Tighten the banjo bolts
securely.
8 Flush the old brake fluid from the system,
refill with new DOT 4 brake fluid and bleed the
air from the system (see Section 8).
9 Check the operation of the brakes before
riding the scooter.
8 Brake hydraulic syste
bleeding and fluid cha~
, -
?rn
-
nae
Bleeding
Caution: Support the machine in a upright
position a n d turn the handlebars so that
the hydraulic reservoir i s level while
carrying-out these procedures.
1 Bleeding the brakes is simply the process
of removing air from the brake fluid reservoir,
master cylinder, the hose and the brake
caliper. Bleeding is necessary whenever a
brake system connection is loosened, or
when a component is replaced or renewed.
Leaks in the system may also allow air to
enter, but leaking brake fluid will reveal their
presence and warn you of the need for repair.
2 To bleed the brake, you will need some new
DOT 4 brake fluid, a small container partially
filled with clean brake fluid (from a freshly
opened container), a length of clear vinyl or
I
A.
7.6
Ensure the brake hose is routed
correctly
plastic hose, some rags and a spanner to fit
the brake caliper bleed valve.
3
Remove the handlebar covers for access to
the fluid reservoir (see Chapter 7) and cover
any painted components to prevent damage
in the event that brake fluid is spilled.
4 Remove the reservoir cover, diaphragm
plate and diaphragm and slowly pump the
brake lever a few times, until no air bubbles
can be seen floating up from the holes in the
bottom of the reservoir. This bleeds air from
the master cylinder end of the line.
Temporarily refit the reservoir cover.
5 Pull the dust cap off the caliper bleed valve
(see illustration). Attach one end of the clear
vinyl or plastic hose to the bleed valve and
submerge the other end in the brake fluid in
the container (see illustration). Note: To
avoid damaging the bleed valve during the
procedure, loosen i t and then tighten i t
temporarily with a ring spanner before
8.5a Pull the dust cap off the bleed valve
8.5b
. . .
and attach the hose
(arrowed)
. . .
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