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SERVICE INFORMATION
GENERAL
BRAKE SYSTEM
ACAUTION
Frequent
inhalation of brake
lining
or
pad
dust,
regardless of
malerial
composition could
be hazardous to
your
health
.
•
Avoid breathing
dust
particles.
•
Never use
an air
hose
or
brush
to dean brake assemblies. Use an
OSHA-approved
vacuum cleaner.
NOTICE
Spilled brake fluid will severely damage
the
plastic pans and painted surfaces. It is also harmful
to
some rubber
pans.
Be
careful whenever
you
remove
the
reservoir cap: make sure
the
reservoir
;s
horizontal
first.
•
A
contaminated brake
lining, drum,
disc or
pad reduces
stopping
power. Discard
contaminated
linings
or pads, and
dean a contaminated drum
or
disc with a high quality brake digreasing
agent.
•
Check the brake
system
by
applying
the brake leve
r
after
the
air
bleeding.
•
Never
allow
contaminates
(dirt,
water, etc.) to get
into an open
reservoir.
•
Once the hydraulic
system
has been
opened, or
if the brake feels
spongy,
the
system
must be bled.
•
Always use fresh DOT 4
brake
fluid from a
sealed
container
when servicing
the
system.
Do not mix different types
of
fluid
as
they may not
be compatible.
•
Always check brake
operation
before
ridi
ng the
vehicle.
SPECIFICATIONS
Front
brake
ITEM
Recommended brake fluid
Master
cylinder
I.D.
Unit
:
mm
(i n)
ST~A~
N
:
D
~
A
~
R D
~
~~======~S
~ E~ R~
V
~
' C
~
E~L
~
'M
~
'T~
DOT 4 brake flui~
14.000 -
14.043 (0.55'2
0.55,'",9ii-1
_ _
~_';;4Ci'0i>5"5-ii10<i.5,,5",,,331
13.957
-
13.984 (0.5495 -
0.55061'
_ _
-+--';
' :i'3
' i< 94i'5TiI"
O.,,54
i.9iiO~1
3396
34 01(1337
,
339)
34 02
(1
3394)
-
-
Master
cylinder
0.0.
Caliper cylinder
I D
r--
Caliper cy linder piston 0.0.
I
33.878
33.928 (1.3338
1.3357)
33.8711.3 335)
Brake disc thickness
3.8
-
4.2
(0.
15
-
0.17)
3.5
(0.
14)
Brake
disc
Rear
brak~Drum
1.0.
runout
-
0.10
(0.0
180.0 ·
180.2
(7.086-7.095)
181
(7.11
ckness
5.3 - 5.32 (0.209 -
0.2 17)
To
index
r
Uning
thi
Rear
(park
Rear brak
- -
ingl
brake
lever
freeplay
15
- 20
(9/16
-13116)
-
e pedal freeplay
TORQUE VALUES
Brake hose
oil bolt
Front
master cylinder
reservoir
cap
screw
Front
brake
lever pivot bolt
Front
brake lever
pivot nut
Front
brake switch screw
Front
master cylinder holder
bolt
Front
brake caliper mounting bolt
Front
brake caliper slide pin
bolt
Splash guard
Rear brake
arm
pinch
bolt
Rear
wheel hub nut
Front
brake bleed valve
Brake
pipe joint (green
surface)
Brake
pipe joint
(black
surface)
15-20
(9/16-13116)
34 N·m
(3.5
kgf·m,
25lbf·ftj
2
N·m
(0.2
kgf·m,
1.4 Ibf·ft)
1.0 N'm
(0.1
kgf·m,
0.7Ibf·ft)
5.9
N'm
(0.6 kgf·m,
4.4 Ibf·ft)
1.2 N'm
(0.
1
kgf·m,
0.9
Ibf·ft)
12 N
'm
(1.2
kgf·m,
9Ibf·ft)
44 N'm
(4.5
kgf·m
,
33 Ibf·ft)
23 N'm
12.3
kgf.m,
17
Ibf·ft)
11
N'
m
(1.1
kgf·m
,
8Ibf·ft)
20 N'm
(2.0 kgf·m,
14 Ibf·ft)
137 N'm
(14.0
kgf·m
, 101Ibf·ft)
5.4
N 'm
(0.6 kgf·m, 4.0
Ibf.ft)
17
N'm
(1.7 kgf.m, 13Ibf.ft)
14 N'm
(1.4
kgf·m
,
10 Ibf·ft)
Apply
locking
agent
to the
threads
Aloe
bolt: replace
with a
new
one
Castle
nut
16-3
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