ABS Troubleshooting Outline............................................................................................
Inquiries to Rider...............................................................................................................
Self-diagnosis Outline .......................................................................................................
Self-diagnosis Procedures ................................................................................................
Service Code Clearing Procedures...................................................................................
How to Read Service Codes.............................................................................................
How to Erase Service Codes ............................................................................................
Yellow ABS Indicator Light (LED) Inspection ....................................................................
ABS Unit Solenoid Valve Inspection (Service Code 13, 14, 17, 18) .................................
ABS Solenoid Valve Relay Inspection (Service Code 19) ................................................
Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code 25) .............
ABS Motor Inspection (Service Code 35) .........................................................................
Wheel Rotation Sensor Signal Abnormal Inspection (Front: Service Code 42) (Rear:
Service Code 44) ...........................................................................................................
Front or Rear Wheel Rotation Sensor Wiring Inspection (Service Code 43) ....................
Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)..................................
Power Supply Voltage Abnormal Inspection (Service Code 52: Low Voltage) (Service
Code 53: High Voltage)..................................................................................................
ABS Hydraulic Unit Internal Error Inspection (Service Code 55) ......................................
ABS Hydraulic Unit Removal ............................................................................................
ABS Hydraulic Unit Installation .........................................................................................
ABS Hydraulic Unit Inspection ..........................................................................................
Front Wheel Rotation Sensor Removal ............................................................................
Front Wheel Rotation Sensor Installation .........................................................................
Rear Wheel Rotation Sensor Removal .............................................................................
Rear Wheel Rotation Sensor Installation ..........................................................................
Wheel Rotation Sensor Inspection....................................................................................
Wheel Rotation Sensor Air Gap Inspection ......................................................................
Wheel Rotation Sensor Rotor Inspection..........................................................................
Fuse Removal...................................................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................

12-31
12-33
12-36
12-40
12-40
12-41
12-44
12-44
12-46
12-49
12-49
12-49
12-50
12-50
12-51
12-53
12-55
12-55
12-56
12-57
12-58
12-58
12-59
12-59
12-61
12-61
12-62
12-62
12-62
12-62
12-62

BRAKES 12-3
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12-4 BRAKES
Exploded View

BRAKES 12-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12

Fastener
Brake Hose Clamp Bolt
Brake Hose Banjo Bolts
Front Brake Reservoir Cap Screw
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Front Brake Light Switch Screw
Front Master Cylinder Clamp Bolts
Front Brake Disc Mounting Bolts
Front Caliper Mounting Bolts
Front Brake Pad Pins
Front Caliper Assembly Bolts
Bleed Valves

B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.

N·m
6.9
25
1.5
1.0
5.9
1.2
11
27
25
17
22
5.4

Torque
kgf·m
0.70
2.5
0.15
0.10
0.60
0.12
1.1
2.8
2.5
1.7
2.2
0.55

ft·lb
61 in·lb
18
13 in·lb
8.9 in·lb
52 in·lb
11 in·lb
97 in·lb
20
18
13
16
48 in·lb

Remarks

Si

S
L, S

L

12-6 BRAKES
Exploded View

BRAKES 12-7
Exploded View
No.
1
2
3
4
5
6
7
8
9
10

Fastener
Brake Hose Banjo Bolts
Rear Caliper Pin Bolt
Bleed Valve
Rear Brake Pad Pin
Rear Caliper Mounting Bolt
Rear Master Cylinder Push Rod Locknut
Brake Pedal Bolt
Rear Master Cylinder Mounting Bolts
Rear Brake Disc Mounting Bolts
Rear Wheel Rotation Sensor Bolt

B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.

N·m
25
27
5.4
17
22
17
8.8
25
27
6.9

Torque
kgf·m
2.5
2.8
0.55
1.7
2.2
1.7
0.90
2.5
2.8
0.70

ft·lb
18
20
48 in·lb
13
16
13
78 in·lb
18
20
61 in·lb

Remarks

Si

L, S

12-8 BRAKES
Exploded View
ABS Equipped Models

BRAKES 12-9
Exploded View
No.
1
2
3
4
5
6

Fastener
Brake Hose Banjo Bolts
Brake Pipe Banjo Bolts
ABS Hydraulic Unit Bracket Bolts
ABS Hydraulic Unit Bolts
Front Wheel Rotation Sensor Rotor Bolts
Front Wheel Rotation Sensor Bolt

R: Replacement Parts

N·m
25
33
8.8
8.8
4.15
6.9

Torque
kgf·m
2.5
3.4
0.90
0.90
0.423
0.70

ft·lb
18
24
78 in·lb
78 in·lb
37 in·lb
61 in·lb

Remarks

12-10 BRAKES
Specifications
Item
Brake Lever, Brake Pedal
Brake Lever Position
Brake Lever Free Play
Pedal Free Play
Pedal Position
Brake Pads
Lining Thickness:
Front
Rear
Brake Discs
Thickness
Runout
Brake Fluid
Grade
ABS (Equipped Models)
ABS Hydraulic Unit:
Make
Wheel Rotation Sensor Air Gap:
Front
Rear

Standard
5-way adjustable (to suit rider)
Non-adjustable
Non-adjustable
About 50 mm (2.0 in.) below top of
footpeg

4 mm (0.16 in.)
5 mm (0.20 in.)
4.8  5.2 mm (0.19  0.20 in.)
TIR 0.15 mm (0.0059 in.) or less

Service Limit
–
–
–
–

–
–
–
–

–
–
–
–

1 mm (0.04 in.)
1.4 mm (0.06 in.)
4.5 mm (0.18 in.)
TIR 0.3 mm (0.013 in.)

DOT4

– – –

NISSIN

– – –

0.2  1.5 mm (0.01  0.06 in.)
0.2  1.5 mm (0.01  0.06 in.)

– – –
– – –

BRAKES 12-11
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever adjuster has 5 positions so that the brake
lever position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to align
the number with the arrow mark [B] on the lever.
○The distance from the grip to the lever is minimum at number 5 and maximum at number 1.

•

Brake Pedal Position Inspection

that the brake pedal [A] is in the correct position.
• Check
Footpeg [B]
Pedal Position
Standard: About 50 mm (2.0 in.) [C] below top of
footpeg

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment
NOTE

○Usually it is not necessary to adjust the pedal position,
but always adjust it when the push rod locknut has been
loosened.
the locknut [A] and turn the push rod with the hex
• Loosen
head [B] to achieve the correct pedal position.

•

If the length [C] shown is 70 ±1 mm (2.8 ±0.04 in.), the
pedal position will be within the standard range.
Tighten:
Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m
(1.7 kgf·m, 13 ft·lb)

the brake light switch operation (see Brake Light
• Check
Switch Operation Inspection in the Periodic Maintenance
chapter).

Brake Pedal Removal

• Remove:
Right Front Footpeg Bracket Bolts [A]

12-12 BRAKES
Brake Lever, Brake Pedal

• Remove:
Cotter Pin [A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]
Brake Pedal Bolt [E]
Brake Pedal [F]

Brake Pedal Installation

grease to the brake pedal pivot shaft [A] and install
• Apply
the washer [B].
• Install:
Brake Pedal [C]

•

Washer [D]
Tighten:
Torque - Brake Pedal Bolt [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

the return spring [A] and the rear brake light switch
• Install
spring [B] as shown.
Front Footpeg Bracket [C]
Brake Pedal [D]
Rear Brake Light Switch [E]

grease to the joint pin [A], and install it.
• Apply
the cotter pin [B] with a new one.
• Replace
Insert
the
pin and bend the pin ends [C].
• Install the cotter
right
front
footpeg bracket to the frame.
• Tighten:
•
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)

the brake pedal position (see Brake Pedal Position
• Check
Inspection).

BRAKES 12-13
Calipers
Front Caliper Removal

ABS equipped models, note the following.
•○For
Free the front wheel rotation sensor lead [A] from the

•
•

clamp [B].
Loosen the banjo bolt [C] at the brake hose lower end,
and tighten it loosely.
Remove the caliper mounting bolts [D], and detach the
caliper [E] from the disc.

NOTICE
Do not loosen the caliper assembly bolts. Take out
only the caliper mounting bolts for caliper removal.
Loosening the caliper assembly bolts will cause
brake fluid leakage.
the banjo bolt and disconnect the brake hoses
• Remove
from the caliper.

○Temporarily secure the end of the brake hose to some
high place to keep fluid loss to a minimum.

NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

Rear Caliper Removal

the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the rear caliper mounting bolt [B], and detach the
• Remove
caliper [C] from the disc.
the banjo bolt and disconnect the brake hose
• Remove
from the caliper.

○Temporarily secure the end of the brake hose to some
high place to keep fluid loss to a minimum.

NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

Caliper Installation

the caliper and brake hose lower end.
•○Install
Replace the washers on each side of hose fitting with new
ones.

○Touch the brake hoses to the stopper of the caliper.

12-14 BRAKES
Calipers
Rear Caliper
Install:
Dust Boot [A]
Guide [B]

•

silicone grease to the rear caliper pin bolt.
• Apply
Fit
the
rear brake pads [A] to the guide [B].
•

• Tighten:
Torque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Caliper Mounting Bolt: 22 N·m (2.2 kgf·m, 16
ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

the front wheel rotation sensor lead correctly (see
• Run
Cable, Wire, and Hose Routing section in the Appendix

•
•
•

chapter).
Check the fluid level in the brake reservoirs.
Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag,
and no fluid leakage.

WARNING
After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.

Front Caliper Disassembly

to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Front Caliper Assembly

to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Rear Caliper Disassembly

to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

BRAKES 12-15
Calipers
Rear Caliper Assembly

to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Caliper Fluid Seal Damage Inspection