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H Y D RA U LI C D I S K B R A K E
S ERVICE I N FORMATION
TROU BLES H O OTI N G
BRAKE F L U I D R EPLACEM ENT/
AIR BLEED I N G
SERVICE I N FORMATION
G E N E RAL
•
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
4
•
Use only DOT
brake fluid.
•
The brake caliper can be removed without disconnecting the hydraulic system.
•
Once the hydraulic system has been disassembled, or if the brakes feel spongy, the system must be bled.
•
Do not allow foreign material to enter the system when filling the reservoir.
•
Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubber
parts by covering them with a shop towel. I f fluid does get on these parts, wipe it off immediately with a clean cloth.
•
A lways check brake operation before riding the motorcycle.
•
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA -approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard
caused by airborne asbestos fibers.
S P E C I F I CAT I O N S
ITEM
Disc thickness
Disc runout
' 8 8,'89,
' 9 1 - ' 9 3 :
Master
cylinder
After ' 9 3 :
' 88,'89,
' 9 1 -'93 :
B rake
caliper
After ' 9 3 :
T O R Q U E VA L U E S
Caliper mounting bolt
Brake hose oil bolt
Bleed valve
M aster cylinder holder bolt
Master cylinder cover screw
T O O L
Special
Snap ring pliers
1 4- 2
1 4- 2
1 4- 3
1 4- 4
I. D.
1 2. 7 00- 1 2 .743 (0.5000-0. 50 1 7 )
piston O.D.
1 2 . 6 5 7 - 1 2 .684(0.4983-0.4994)
I . D.
1 1 .0- 1 1 .043 (0.433 1 -0.4348)
piston O.D.
1 0.9 5 7-1 0.984(0.43 1 4-0.4324)
cylinder I . D .
30.2 3 0-30.280( 1 . 1 902 - 1 . 1 92 1 )
piston O.D.
30. 1 6 5-30. 1 9 8 ( 1 . 1 8 7 6- 1 . 1 8 8 9 )
cylinder I . D.
2 7 .000-2 7 .050( 1 .0630- 1 .06 50)
piston O.D.
2 6.93 5-2 6 . 9 6 8 ( 1 .604- 1 .06 1 7 )
27 N • m ( 2 . 7 kg-m , 20 ft-lb)
30 N·m (3.0 kg-m, 22 ft-lb)
5 . 5 N · m (0. 5 5 kg-m, 4 ft-lb)
1 2 N·m ( 1 . 2 kg-m, 9 ft-lb)
1 . 5 N·m (0 . 1 5 kg-m, 1 . 1 ft-lb)
07 9 1 4 - 32 3000 1 or equivalent commercia lly
BRAKE PAD/DISC
MASTER CYL I N D E R
BRAKE CALIPER
STAN DA R D
5.0(0.2 )
-
available in U . S . A .
1 4- 5
1 4- 8
1 4-1 1
U n it: m m ( i n )
E R V I C E LI M IT
4.0(0. 1 6)
0.30(0.0 1 2 )
1 2 . 7 6 (0.502 )
1 2 . 6 5 (0.498 )
1 1 .05(0.43 5 )
1 0.94 5 ( 0.4309)
30.2 9 ( 1 . 1 93 )
3 0. 1 6 ( 1 . 1 87 )
2 7 .06 ( 1 .065 )
2 6.93 ( 1 .060)
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Table of Contents
Troubleshooting
