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394
times as
it
takes to
refill
the caliper
cylinder
and
cor-
rectly locate
the
brake pads
again
st the
disc.
NOTE
To
control
tlte smallflow ojhydraulic
fluid,
punch
a small
hole into the
brake
fl nid
container
sea / nex t
to the
edge oj
tlte
pOllr spout.
This
will help
eliminate flu
id spills,
especially whil
e
adding
fluid to
the
Vet)'
small
brake
res
ervoi
r.
/I~IRNING
Use hrakejluid clearly
marked
DOT3
f
rom a
se
aled conta iner:
Other types
may
vaporize ami
cause
brake.failure
.
Always
use the
same brand
name;
do
n01
intermix,
as
many
brands
are
1101
co
mpatible.
Do
110
1
intermix
s
ili-
cone-based
(DOT
5) brake
fluid,
as it
can cause brak
e
comp
onent
damage
leading
1
0
bra
ke system
fa
ilure.
2
1. Refill
the master
cylinder
reservoir,
if
neces-
sary,
to
maintain
the
correct
fluid
level
as
indicated
on
the
side
of
the
reservoir.
Install
the
diaphragm
and
coverand
tighten the
screws
securely.
22.
Connect
the
foot
brake
lever
linkage
rod
ontn
caliper.
23.
Install front
and
rear
fenders
and
seat
as
de-
scribed
in
Chapter
Filleen.
WA
RNING
Make
sure
the
brakes are operating
co
rrectly with
filII
hydraulic
advan-
tag e before riding the
vehicle.
If
lIec-
essary.
bleed the
brakes as des
cribed
in
this
chap ter.
NOTE
The
following
instruc tions
apply
to
original
equipment-o pe
pads
only.
If
using afterma
rket
brake
pa
ds
. fo
llow
the manufacturer
s
break-in
instruc-
tions.
24.
Bed
the
pads in gradually
with
a burnishing
procedure as
follows:
a.
Start the
vehicle
and
slowly increase speed up
to
30 mph
(48
km/h).
b.
Gradua
lly
apply
the
brakes and
bring the ve-
hicle to a complete
stop.
c.
Repeat
this
procedure
10
times.
C
HAPTEI( FOU RT EEN
d. For the
first
2-3
days
of
riding, use
only
light
pressure
as
much
as possible. Immediate hard
application
will
glaze
the new
friction
pads
and
greatly
reduce the
effectiveness
of
the
brake.
OUT
I'UT
SHAF T BRAKE CALI PE R
(1996-1997
MODELS)
Rcmov
aIIInstall ation
Refer to
Figure
28.
CAUTION
Do not sp
ill
allY
brake
f
luid
0/1
the
frame. flash
off all)' sp illed
brake
fluid
immediately; it
1I'i11
destroy the
finish
.
Use
soapy
water
and
rinse
completely.
NOTE
If
the
caliper is not going to be disa
s -
sembledfo
r service,
proceed to Step
2.
I.
If
the
caliper assembly
is going to be disassem-
bled
for service, perform the
following:
a.
Remove
the brake pads as described
in
this
chapter.
b.
Reinstall
the caliper
assembly
and
tighten
the
caliper mounting
bolts
securely.
CA
UTI ON
Do
not
allo
w
the
piston
to travel
out
far
enough
to
co
me
in
contact
with tile
brake
disc.
If this
happ
ens the
piston
may
scratch or
go
uge the
(lise
durin
g
caliper removal.
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