Service Information - Honda INTERCEPTOR 2002 Service Manual

HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL
A
CAUTION
Frequent inhalation of brake pad dust, regardless of mat erial com position could be hazardous to your health.
• Avoid breathi ng dust particles.
• Never use an air hose or brush to clea n brake assemblies. Use and OSHA-approved vacuum cleaner.
• This model is equipped with a Lin ked Brake System. The system air bleeding proced ure on page 15-7 must be fo llowed.
• cio not d isassemble t he secondary master cylinder push rod or the correct brake performa nce will not be obtained.
• A contaminated brake disc o r pad reduces st opping power. Discard contaminated pads and clean a contaminated disc
with a hi gh qual ity brake degreasi ng agent.
• Check t he brake system by applying the brake lever o r pedal after the air bleedi ng.
• Spilled brake f luid will severely dam age instrument lenses and painted surfaces. It is also harmf ul t o some rubber parts.
Be caref u l whenever you remove the reservoir cap; make sure t he f ront reservoir is horizontal first.
• Never al low contaminates (dirt, water, etc.) to get into an open reservoir.
• Once the hydrau lic system has been opened, or if t he brake fee ls spongy, the system m ust be b led.
• A lways use fresh DOT 4 brake fluid from a sealed container when servicing t he system. Do not m ix different types of
fluid, they may not be com pat ible.
• A lways check brake operat ion before r idi ng the mot orcycle.
• This sect ion covers service of t he standard brake components (including LBS) of the brake system. See page 16-3 for
ABS service.
• T he brake fluid replacement procedure fo r the ABS model shou ld be perform ed in the same manner as in the standard
model. Note t hat there is no brake flu id in t he ABS m odulator (except in the modulator head), because the modu lator is
the motor-driven hydraulic pressure type. Therefore, brake fluid rep lacement and bleeding air from t he modulator body
is not necessary.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
I
Front
Specified brake f luid Honda DOT 4 brake f luid
-
Brake disc thickness 4.5 (0. 18) 3.5 (0.14)
Brake disc warpage
-
0.20 (0.008)
Master cylinder 1.0.
14.000 - 14.043 (0.5512- 0.5529) 14.055 (0.5533)
Master piston O. D. 13.957- 13.984 (0.5495- 0.5506) 13.945 (0.5490)
Secondary master cylinder I. D. 12.700- 12.743 (0.5000 - 0.5017) 12.76 (0.502)
Secondary master piston 0.0.
12.657 - 12.684 (0.4983 - 0.4994)
12.65 (0.498)
Left caliper cylinder I. D.
Upper 25.400 - 25.450 (1.0000- 1.0020) 25.460 (1.0024)
Middle 25.400- 25.450 (1.0000 - 1.0020) 25.460 (1.0024)
Lower 25.400- 25.450 (1.0000 - 1.0020) 25.460 (1.0024)
Left caliper piston 0.0. Upper 25.318 - 25.368 (0.9968- 0.9987) 25.310 (0.9965)
Midd le 25.318-25.368 (0.9968- 0.9987) 25.310 (0.9965)
Lower 25.3 18-25.368 (0.9968 - 0.9987) 25.310 (0.9965)
Right caliper cylinder Upper 25.400- 25.450 (1.0000 - 1.0020) 25.460 (1.0024)
1.0.
Middle
22.650 - 2 2.700 (0.8917 - 0.8937) 22.710 (0.8941 )
Lower
25.400 - 25.450 (1.0000- 1.0020) 25.460 (1.0024)
Right caliper piston
Upper 25.318- 25.368 (0.9968 - 0.9987) 25.310 (0.9965)
0.0.
Middle
22.585 - 22.618 (0.8892 - 0.8905) 22.560 (0.8882)
Lower 25.318 - 25.368 (0.9968- 0.9987) 25.310 (0.9965)
Rear Specified brake f luid
Honda DOT 4 brake f luid
-
Brake pedal height 90.0 (3.54) -
Brake disk t hickness
6.0 (0.23) 5.0 (0.20)
Brake disc warpage
-
0.30 (0.012)
Master cylinder
I.
D.
17.460- 17.503 (0.6874 - 0.6891) 17.515 (0.6896)
Master piston 0.0.
17.417 - 17.444 (0.6857 - 0.6868) 17.405 (0.6852)
Caliper cylinder I. D.
Front 25.400- 25.450 (1.0000 - 1.0020) 25.460 (1.0024)
Center
25 .400 - 25.450 (1.0000 - 1.0020) 25.460 (1.0024)
Rear
25.400 - 25.450 (1.0000- 1.0020) 25.460 (1.0024)
Ca li per piston O. D. Front
25.318 - 25.368 (0.9968- 0.9987) 25.310 (0.9965)
Cent er
25.318- 25.368 (0.9968 - 0.9987) 25.310 (0.9965)
Rear 25.318- 25.368 (0.9968 - 0.9987)
25.310 (0.9965)
15-4