The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.

•

Caliper Dust Seal Damage Inspection

that the dust seals [A] are not cracked, worn,
• Check
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.
Pistons [B]
Fluid Seals [C]

12-16 BRAKES
Calipers
Rear Caliper Dust Boot and Friction Boot Damage
Inspection

that the dust boot [A] and friction boot [B] are not
• Check
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.

Caliper Piston and Cylinder Damage Inspection

inspect the pistons [A] and cylinder surfaces [B].
• Visually
Replace the caliper if the cylinder and piston are badly
scores or rusty.

Rear Caliper Holder Wear Inspection
The caliper body must slide smoothly on the rear caliper
pin bolt [A] and sleeve [B]. If the body does not slide
smoothly, one pad will wear more than the other, pad wear
will increase, and constant drag on the disc will raise brake
and brake fluid temperature.
Check to see that the rear caliper pin bolt and the sleeve
are not badly worn or stepped, and that the rubber boots
are not damaged.
If the rear caliper pin bolt is damaged, replace the rear
caliper pin bolt.
If the sleeve is damaged, replace the sleeve.
If the rubber boots are damaged, replace the rubber boot.

•

BRAKES 12-17
Brake Pads
Front Brake Pad Removal

• Remove:
Pad Pin [A]

Pad Spring [B]
Brake Pads [C]

Front Brake Pad Installation

the caliper pistons in by hand as far as they will go.
• Push
silicone grease to the stopper ring of the pad pin.
• Apply
Install
• shown.the outside pad [A] and insert the pad pin [B] as

• Set:
Inside Pad [A]
Pad Spring [B]

○Push down the pin holder [C] and insert the pad pin.

• Tighten:

Torque - Front Brake Pad Pin: 17 N·m (1.7 kgf·m, 13 ft·lb)

WARNING
After servicing, it takes several applications of the
brake lever 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 is obtained by pumping the lever until
the pads are against the disc.

Rear Brake Pad Removal

the pad pin [A].
• Loosen
Remove
rear caliper mounting bolt [B].
• Turn the the
rear
• Remove: caliper [C] forward.
• Pad Pin
Brake Pads [D]

12-18 BRAKES
Brake Pads
Rear Brake Pad Installation

that the pad spring [A] is in place on the rear
• Check
caliper.

silicone grease to the stopper ring of the pad pin
• Apply
[A].
the pad pin through the brake pads [B] and tighten
• Insert
the pad pin temporarily.
the brake pads to the guide [C].
• Fit
Tighten:
•
Torque - Rear Caliper Mounting Bolt: 22 N·m (2.2 kgf·m, 16
ft·lb)
Rear Brake Pad Pin: 17 N·m (1.7 kgf·m, 13 ft·lb)

WARNING
After servicing, it takes several applications of the
brake 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 pedal is obtained by pumping the pedal until
the pads are against the disc.

Brake Pad Wear Inspection

to the Brake Pad Wear Inspection in the Periodic
• Refer
Maintenance chapter.

BRAKES 12-19
Master Cylinder
Front Master Cylinder Removal

the banjo bolt [A] to disconnect the brake hose
• Remove
from the master cylinder.

○Temporarily secure the end of the brake hose to some

•
•

high place to keep fluid loss to a minimum.
Remove the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, brake lever, and
brake switch installed.
Disconnect the front brake light switch connectors [D].

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

Front Master Cylinder Installation

the front master cylinder to match its mating surface
• Set
[A] to the punch mark [B] of the handlebars.
the upper clamp bolt first, and then the lower
• Tighten
clamp bolt.
Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1
kgf·m, 97 in·lb)

the front brake light switch connectors.
• Connect
Replace
that are on each side of the hose
• fitting withthenewwashers
ones.
the brake hose.
•○Install
Touch the brake hose to the stopper of the front master

•

cylinder.
Tighten:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

the brake line (see Brake Line Bleeding).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.

Rear Master Cylinder Removal

the brake hose banjo bolt [A] and disconnect the
• Remove
brake hose from the rear master cylinder.

○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.

• Remove:
Right Front Footpeg Bracket Bolts [B]

12-20 BRAKES
Master Cylinder

• Remove:
Right Heel Guard Bolts [A], Nuts and Washers
Right Heed Guard [B]

the right front footpeg bracket bolts temporarily.
• Tighten
Remove:
• Rear Master Cylinder Mounting Bolts [A]

• Remove:
Right Front Footpeg Bracket Bolts
•
•

Cotter Pin [A]
Joint Pin [B]
Slide the clamp [C].
Disconnect the reservoir hose lower end, and drain the
brake fluid into a container.

Rear Master Cylinder Installation

the reservoir hose lower end, and install the clamp.
• Install
Replace
cotter pin [A] with a new one.
• Insert thethecotter
pin and bend the pin ends [B].
•

the right front footpeg bracket bolts temporarily.
• Tighten
• Tighten:
Torque - Rear Master Cylinder Mounting Bolts [A]: 25 N·m
(2.5 kgf·m, 18 ft·lb)

NOTE

○Depress the brake pedal [B] and then align the holes of
the master cylinder [C].

BRAKES 12-21
Master Cylinder

• Remove:
Right Front Footpeg Bracket Bolts
• Install:
Right Heed Guard [A]
•

Washers [B]
Right Heel Guard Bolts [C] and Nuts [D]
Tighten:
Torque - Heel Guard Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)
Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)

the washers that are on each side of the hose
• Replace
fitting with new ones.
the brake hose.
•○Install
Touch the brake hose to the stopper of the rear master

•

cylinder.
Tighten:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

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

Front Master Cylinder Disassembly

to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.

Master Cylinder Assembly

to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.

12-22 BRAKES
Master Cylinder
Master Cylinder Inspection (Visual Inspection)

the master cylinders (see Front/Rear Master
• Remove
Cylinder Removal).
the front and rear master cylinders (see
• Disassemble
Master Cylinder Rubber Parts Replacement in the Peri-

•
•

•
•
•

odic Maintenance chapter).
Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.
Check the dust covers [E] for damage.
If they are damaged, replace them.
Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [I]
Rear Master Cylinder [J]

BRAKES 12-23
Brake Disc
Brake Disc Removal

the wheels (see Front/Rear Wheel Removal in
• Remove
the Wheels/Tires chapter).
the brake disc mounting bolts [A], and take off
• Remove
the disc [B].
the wheel rotation sensor rotor [C] only rear
• Remove
brake disc.

Brake Disc Installation

the brake disc on the wheel so that the marked side
• Install
[A] faces out.
the wheel rotation sensor rotor on the brake disc
• Install
so that the marked side faces out only rear brake disc.
a non-permanent locking agent to the threads of
• Apply
the front and rear brake disc mounting bolts.
the front and rear brake disc mounting bolts fol• Tighten
lowing the specified tightening sequence.
Front Brake Discs [B]
Rear Brake Disc [C]
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)

Brake Disc Wear Inspection

the thickness of each disc [A] at the point where
• Measure
it has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]
Brake Discs Thickness
Standard:
4.8  5.2 mm (0.19  0.20 in.)
Service Limit: 4.5 mm (0.18 in.)

Brake Disc Warp Inspection

the front/rear wheel off the ground with a suitable
• Raise
stand.

○For front disc inspection, turn the handlebars fully to one

•

side.
Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard:

TIR 0.15 mm (0.0059 in.) or less

Service Limit: TIR 0.3 mm (0.013 in.)

12-24 BRAKES
Brake Fluid
Brake Fluid Level Inspection

to the Brake Fluid Level Inspection in the Periodic
• Refer
Maintenance chapter.

Brake Fluid Change

to the Brake Fluid Change in the Periodic Mainte• Refer
nance chapter.

Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.

WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake lever or pedal has a soft or
"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.

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

NOTE

○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.

• Remove:
Front Brake Reservoir Cap Screws [A]
Front Brake Reservoir Cap [B]
Diaphragm Plate
Diaphragm
Fill the reservoir with fresh brake fluid to the upper level
line in the reservoir.
Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.

•
•

BRAKES 12-25
Brake Fluid
the rubber cap [A] from the bleed valve on the
• Remove
caliper.
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.

the brake line and the caliper.
•○Bleed
Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while holding the brake applied.
3. Release the brake [C].

NOTICE
After pumping the brake lever several times, releasing it without opening and closing of the bleed
valve may cause brake fluid to be blown back from
the master cylinder reservoir. Brake fluid spilt
on painted surfaces and plastic parts will quickly
damage them. Be sure to open and close the bleed
valve.

NOTE

○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding.
○Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.
the clear plastic hose.
• Remove
• Install:
Diaphragm

•

Diaphragm Plate
Front Brake Reservoir Cap
Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

12-26 BRAKES
Brake Fluid
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.

○First, tighten the brake reservoir cap [A] clockwise [B] by
hand until slight resistance is felt indicating that the cap is
seated on the reservoir body [C], then tighten the cap an
additional 1/6 turn [D] while holding the brake fluid reservoir body.

the clamp and screw.
• Install
Tighten
the bleed valve, and install the rubber cap.
•
Torque - Bleed Valves: 5.4 N·m (0.55 kgf·m, 48 in·lb)

the fluid level (see Brake Fluid Level Inspection in
• Check
the Periodic Maintenance chapter).
bleeding is done, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.

WARNING
When working with the disc brake, observe the precautions listed below.
Never reuse old brake fluid.
Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to deteriorate.
Do not leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
Do not change the fluid in the rain or when a
strong wind is blowing.
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.
When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on
the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned satisfactorily.
Brake fluid quickly damages painted surfaces;
any spilled fluid should be completely wiped up
immediately.
If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.

•
•
•
•
•
•

•