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4. Carefully move the shield out of the
way; then remove the hairpin clip
securing the brake pads to the cali-
per assembly.
5. Using a pair of pliers, pull the outer
brake pad out of the caliper assembly.
NOTE: Changing one pad at a time
will prevent one piston from pushing
out the other piston from the caliper.
6. Measure the thickness of the brake pad.
The brake pad thickness must be greater
than 1.0 mm (0.04 in.). If the brake pad
thickness is less than specified, replace-
ment of both pads is necessary.
7. Using a flat-blade tool, slowly and
carefully push the piston into the
caliper.
8. Position the outer brake pad into the
caliper; then install the hair-pin clip
into the caliper assembly.
9. Repeat steps 5-8 for the inner pad; then
secure the pad with the hairpin clip.
10. Remove the reservoir cover and
remove the remaining fluid; then fill
the reservoir with fresh fluid and
install the cover.
11. Pump the brake lever to ensure cor-
rect positioning of the brake pads
and proper brake lever travel; then
release.
NOTE: If brake lever travel is not
within specification, bleed the brake
system.
12. Remove the reservoir cover and fill
the reservoir (if necessary) to the
proper level with fresh brake fluid;
then install the cover.
13. Secure the brake shield, the driven
clutch (tightened to 20 ft-lb), and the
rear belt guard; then close and
secure the left-side access panel.
NOTE: When new brake pads are
installed, a "burnishing" process is
required (see Burnishing Brake Pads
sub-section).
Burnishing Brake Pads
PC013
After changing brake pads, the new brake
pads must be burnished to achieve full
braking effectiveness. Braking distance
will be extended until brake pads are
properly burnished.
To properly burnish the brakes, use fol-
lowing procedure:
1. Choose an area sufficiently large to
safely accelerate to 50-65 km/h (30-
40 mph) and to brake to a stop.
NOTE: This procedure can also be
accomplished using a shielded jack
stand.
2. Accelerate to 50-65 km/h (30-40
mph); then compress brake lever to
decelerate to a stop.
NOTE: Lightly apply the brake lever
PC011A
to come to an easy stop; do not over-
apply brakes or "lock up" the track.
3. Repeat procedure 10-15 times allow-
ing some cooling between stops.
NOTE: Do not repeat too soon or
too aggressively as to get the brake
disc "red hot."
Do not attempt sudden stops or put
yourself into a situation where a sud-
den stop will be required until the
brake pads are properly burnished.
NOTE: This procedure stabilizes
the pad material and extends the life
of the pads.
! WARNING
29
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