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Brake pad replacement






• Remove the brake caliper by removing the mounting bolts.

• Remove the pads.

 

CAUTION:

* Do not operate the brake lever while removing the pads.

* Replace the brake pad as a set, otherwise braking perform­ ance will be adversely affected.


 

Tightening torque

®: 30 - 48 N·m

(3.0 - 4.8 kg-m, 21.5 - 35.0 l b-ft)

@: 5 -8 N·m

(0.5 - 0.8 kg-m, 3.5 - 6.0 lb-ft)

©: 6 - 9 N·m

(0.6 - 0.9 kg-m, 4.5 - 6.5 lb-ft)

(Q): 15 - 20 N·m

(1.5 - 2.0 kg-m, 11.0 - 14.5 lb-ft)

SG: Apply SILICONE GREASE.


 

 

CALIPER REMOVAL AND DISASSEMBLY

• Disconnect the brake hose by removing the union bolt and catch the brake fluid in a suitable receptacle.

 

CAUTION:

Never re-use the brake fluid left over from the previous servicing and stored for long periods.

WARNI NG:

Brake fluid, if it leaks, will interfere with safe running and dis­ color painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.

• Remove the caliper mounting bolts and take off the caliper.

• Remove the pads.

 

• Place a rag over the pistons to prevent them from popping out and push out the piston by using an air gun.

CAUTION:

Do not use high pressure air to prevent piston damage.

 

 

• Remove the piston (j), dust seal ® and piston seal ® out of the caliper.

 

CALIPER AND DISC INSPECTION

CALIPER

Inspect the caliper bore wall for nicks, scratches or other damage.

PISTON

Inspect the piston surface for any scratches or other damage.

RUBBER PARTS

Inspect each rubber part for damage and wear.


 

 

 

 

 

 
CD ® ®

 

 

 
Ii


 

 

 
DISC

Using a micrometer, check the disc for wear, its thickness can be checked with disc and wheel in place. The service limits for the thickness of the discs are shown below.

09900-20205: Micrometer (0 - 25 mm)

S. r. (Front): 4.0 mm (0.16 in) ervice imit (Rear): 5.5 mm (0.22 in)

 

 
With the disc mounted on the wheel, check the disc for face runout with a dial gauge, as shown.

09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand

 

Service limit: 0.30 mm (0.012 in)

 

CALIPER REASSEMBLY AND REMOUNTI NG

Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points:

 
CAUTION:

* Wash the caliper components with fresh brake fluid before reassembly.

* Never use cleaning solvent or gasoline to wash them.

* Apply brake fluid to the caliper bore and piston to be in­ serted into the bore.

CALIPER BOLTS

Tighten each bolt to the specified torque. (R efer to page 7-6.)

CAUTION:

Bleed air from the brake system after reassembling the caliper. (Refer to page 2-14.)

NOTE:

 
Before remounting the caliper, push the piston all the way into the caliper.

MASTER CYLINDER REMOVAL AND DISASSEMBLY

• Remove the front brake light switch.


 

• Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Unscrew then union bolt and disconnect the brake hose/master cylinder joint.

CAUTION:

Completely wipe off any brake fluid adhering to any parts of the motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc.

 

• Remove the master cylinder assembly.

 

 

• Remove the front brake lever, reservoir cap and diaphragm.

• Drain brake fluid.

 

 

• Remove the dust seal, then remove the circlip by using the special tool.

09900-06108: Snap ring pliers

 

• Remove the piston/secondary cup, primary cup and spring. (]) Circlip

® Secondary cup

® Piston

@ Primary cup

@ Return spring


 

 

 

 

 

 
 

 

 

 
I ®I1 1

mMNwt -c,


 

 

 
MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other damage.

Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage.

 

MASTER CYLINDER REASSEMBLY AND REMOUNTI NG

 
Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the fol­ lowing points:

CAUTION:

Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and all the parts to be inserted into the bore.

• When remounting the master cylinder on the handlebar, align the master cylinder holder's mating surface CD with

punched mark ® on the handlebar and tighten the upper clamp bolt first as shown.

 

Tightening torque: 5 - 8 N·m

(0.5 - 0.8 kg-m, 3.5 - 6.0 lb-ft)

 


CAUTION:

Bleed air from the brake system after reassembling cylinder. (Refer to page 2-14.)

Adjust the front brake light switch after installation.


 

 

master


 

 

Upper clamp bolt

 

Clearance


 

 


 
FRONT FORK


 

Tightening torque

@: 25 - 35 N·m

(2.5 - 3.5 kg-m,

18.0 - 25.5 lb-ft)

@: 18 - 28 N·m

(1.8 - 2.8 kg-m,

13.0 - 20.0 lb-ft)

©: 15 - 30 N·m

(1.5 - 3.0 kg-m,

11.0 - 21.5 lb- ft)


 

 

 
 
 
r
: d

e
@) Th1342

@ 6'1; -@

L_

 

G: Apply SUPER GREASE " A".

Th 1342: Apply THREAD LOCK " 1342".

 

 

 
REMOVAL

• Remove the front wheel. (Refer to page 7-1.)

• Remove the front fender by removing four screws CD.

• Remove the front fender brace by removing four screws ®·

09900-00401: L-type hexagon wrench


 

 

 
NOTE:

Slightl y loosen the front fork cap bolt CD to facilitate later dis­ assembl y before loosening the front fork clamp bolt.

 

 

 
Loosen the front fork upper and lower clamp bolts.

• Pull down the front forks.

 

DISASSEMBLY

 
Remove the front fork cap bolt.

• Remove the spacer, spring seat and spring out of the in­ ner tube.

 

 

 
Invert the fork and stroke it several times to let out fork oil.

• Hold the fork inverted for a few-minutes to drain oil.

 

While holding the caliper mounting portion CD by vise and remove the damper rod with the special tool and the hexa­ gon wrench.

09900-00401: " L" type hexagon wrench set

09940-34520: T-hand le =

09940-34592: Attachment " G "


 

 

 

• Remove the dust seal and oil seal stopper ring.

 

 

• Separate the inner tube out of the outer tube. CAUTION:

The outer tube and inner tube " anti-friction " metals must be replaced along with the oil seal and dust seal.

 

® Dust seal

® Oil seal stopper ring

© Oil seal

© Oil seal retainer

Anti-friction metal (Outer)

® Anti-friction metal (Inner)

 

 
Remove the damper rod and rebound spring out of the in­ ner tube.

 

INSPECTION

DAMPER ROD RING

Inspect the damper rod ring for wear or damage.


 

 

 

 

r r r r r 1

® ® © © CD ®


 

 

 
INNER AND OUTER TUBES

Inspect the inner tube sliding surface and outer tube sliding surface for any scuffing.

 

FORK SPRING

Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.

Service limit: 262 mm (10.3 in)

 

 

 
REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points:

INNER TUBE METAL

• Hold the inner tube vertically and clean the metal groove and install the metal by hand as shown.


CAUTION:

Use special care to prevent damage to the " Teflon" coated surface of the " anti-friction" metal when installing it.

 

 

DAMPER ROD BOLT

• Replace the gasket with a new one. Apply TH R EAD LOCK " 1342" to the damper rod bolt and tighten it to the speci­ fied torque.

99000-32050: THR EAD LOCK " 1342"

 

Tightening torque: 25 - 35 N·m

(2.5 - 3.5 kg-m, 18.0 - 25.5 lb-ft)

 

 

OUTER TUBE METAL, OIL SEAL AND DUST SEAL

• Clean the metal groove of outer tube and metal outer surface.

• Install the outer tube metal, oil seal retainer and oil seal. 09940-50113: Front fork oil seal installer

CAUTION:

Use special care to prevent damage to the " Teflon" coated surface of the " anti-friction" metal when installing it.


 

Replace

 

 

I

 
THR EAD LOCK " 1342"


 

 

After installing the oil seal, install the oil stopper ring and @

dust seal.

CD Anti-friction metal

® Oil seal retainer ------e-o1-x

® Oil seal ®--+": EN•

® Oil seal stopper ring CD, 1--l

@ Dust seal

 

 

 
FORK OIL

• Use fork oil whose viscosity rating meets the specifications below.

Fork oil type For oil # 10
Fork oil capacity (For E-03, 28 and 33)   494 ml (16.7/17.4 US/Imp oz)
 
Fork oil capacity (For the others)   495 ml (16.7/17.4 US/Imp oz)

 
Hold the front fork vertically and adjust the fork oil level with the special tool.

NOTE:

When adjusting oil level, remove the fork spring and com­ press the inner tube fully.

 
For E-03, 28 and 33 106 mm (4.17 in)
For the others 105 mm (4.13 in)

 

09943-74111: Fork oil level gauge Fork oil level

• Tighten the front fork cap bolt to the specified torque. (R efer to page 7-11.)

 

FRONT FOR K REINSTALLATION

• When installing the front fork assembly, set the upper surface

® of inner tube to the upper surface @ of the steering stem head bracket.

 

 
FRONT FOR K CLAMP BOLTS

• Tighten the front fork upper and lower clamp bolts to the specified torque.

09900-00410: Hexagon wrench set

 

TIGHTENI NG TORQUE

CD (Front fork upper clamp bolt):

40 - 60 N-m (4.0 - 6.0 kg-m, 29.0 - 43.5 lb-ft)

Cl) (Front fork lower clamp bolt):

28 - 44 N-m (2.8 - 4.4 kg-m, 20.0 - 32.0 lb-ft)


 

 

• The tria ngle ma rk on the fender brace faces f ront side.

 

 
NOTE:

Before tightening the front fender brace mounting screws, move the front fork up and down 4 or 5 times.

 






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