Wheel Rotation Sensor Air Gap

Standard
Adjustable type (to suit rider)
Non-adjustable
Non-adjustable
About 65 mm (2.6 in.) below top of
footpeg

3.7 mm (0.15 in.)
4.5 mm (0.18 in.)
4.8  5.2 mm (0.19  0.20 in.)
TIR 0.15 mm (0.006 in.) or less

Service Limit
–
–
–
–

–
–
–
–

–
–
–
–

1 mm (0.04 in.)
1 mm (0.04 in.)
4.5 mm (0.18 in.)
TIR 0.3 mm (0.01 in.)

DOT4

– – –

BOSCH
0.4  1.6 mm (0.02  0.06 in.)

– – –
– – –

BRAKES 12-9
Special Tool
Bearing Driver Set:
57001-1129

12-10 BRAKES
Brake Lever, Brake Pedal
Brake Lever Removal/Installation

a thin flat tip screwdriver [A], remove the front brake
• Using
light switch [B].

• Remove:
Brake Lever Pivot Bolt Locknut [A]
Brake Lever Pivot Bolt [B]
Brake Lever Assembly [C]

the lever collar [A] with the bearing driver set [B]
• Press
from the lower side of the lever.
Crimping Point [C]
No Crimping [D]
Special Tool - Bearing Driver Set: 57001-1129

• Remove:
Lever Collar [A]
Knocker [B] with Push Rod Assembly
Lever Spring [C]
Clutch Lever [D]

NOTE

○Be careful not to pop out the lever spring when removing
the lever collar.

NOTICE
Do not adjust the adjuster [A]. That has a bad affect
the brake operation. If turn the adjuster, the brake
master cylinder assembly must be replaced.

BRAKES 12-11
Brake Lever, Brake Pedal

• Install:
Lever Spring [A]
Push Rod Assembly [B]
Knocker [C]

the lever collar [A] with the bearing driver set [B]
• Press
from the upper side of the lever.

○Install the collar so that the end of the collar is flush with
the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129

the push rod [A] of the brake lever to the hole [B] of
• Insert
the master cylinder.
• Check that the push rod is inserted correctly.

silicone grease to the sliding surface of the brake
• Apply
lever pivot bolt [A].
the brake lever pivot bolt locknut [B] with a new
• Replace
one.
the brake lever pivot bolt and brake lever pivot
• Tighten
bolt locknut.
Torque - Brake Lever Pivot Bolt Locknut: 6.0 N·m (0.61
kgf·m, 53 in·lb)

the front brake light switch.
• Install
Confirm
the front brake light switch is held after installing
• it. Replace
the front brake light switch that its fitting dete-

•

riorated.
Check that the pin of the front brake light switch moves
smoothly.

12-12 BRAKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever position can be adjusted to suit the operator’s hand.
Push the lever forward, turn the adjuster [A] and choose
a suitable lever position.

•

Adjuster

Turn in

←

→

Turn out

Far

←

→

Near

Lever
Position

Brake Pedal Position Inspection

that the brake pedal [A] is in the correct position.
• Check
Footpeg [B]
Pedal Position
Standard: About 65 mm (2.6 in.) [C] below top of
footpeg

If it is incorrect, adjust the position.

Brake Pedal Position Adjustment
NOTE

○Usually it is not necessary to adjust the pedal position,
but always adjust it when 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 68 ±1 mm (2.7 ±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:
Rear Master Cylinder Mounting Bolts [A]
Foot Guard [B]
Front Footpeg Bracket Bolts [C]

BRAKES 12-13
Brake Lever, Brake Pedal

• Remove:
Cotter Pin [A]
•

Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]
Remove the brake pedal mounting bolt [E] and take out
the brake pedal.

Brake Pedal Installation

grease to the brake pedal pivot shaft [A].
• Apply
• Install:
Washers [B]

•

Brake Pedal [C]
Tighten:
Torque - Brake Pedal Mounting Bolt [D]: 9.0 N·m (0.92
kgf·m, 80 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]

the cotter pin [A] with a new one.
• Replace
• Insert the cotter pin and bend the pin ends [B].

• Assemble:
Front Footpeg Bracket [A]
•

Rear Master Cylinder [B]
Foot Guard [C]
Rear Master Cylinder Mounting Bolts [D]
Install the footpeg bracket to the frame.
Torque - Front Footpeg Bracket Bolts [E]: 25 N·m (2.5
kgf·m, 18 ft·lb)
Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)

• Install the removed parts (see appropriate chapters).

12-14 BRAKES
Calipers
Front Caliper Removal

the front wheel rotation sensor lead [A] and front
• Free
brake hose [B] from the clamp [C].
the clamp [D] to free the front wheel rotation sen• Remove
sor lead.

the banjo bolt [A] and tighten it loosely to prevent
• Loosen
the fluid spillage.
the caliper mounting bolts [B], and detach the
• Remove
caliper [C] from the disc.
the banjo bolt and disconnect the brake hose
• Remove
from the caliper.

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

○Take care not to spill the brake fluid on the painted or
plastic parts.

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

○Immediately wash away any brake fluid that spills.
Front Caliper Installation

the washers that are on each side of the hose
• Replace
fitting with new ones.
install the front caliper mounting bolts so that
• Temporarily
the seating surface of the bolt do not contact the caliper.
the brake hoses and front wheel rotation sensor lead
• Run
correctly (see Cable, Wire, and Hose Routing section in
the Appendix chapter).

○Avoid sharp bending, kinking, flatting or twisting.
the projection [A] of the left brake hose so that
• Position
the projection end faces flat part [B] as shown.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

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

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.

BRAKES 12-15
Calipers
the brake lever slowly and hold it with a band
• Squeeze
[A].

the front caliper mounting bolt [A] [B] following
• Tighten
specified tightening sequence.
Tightening Sequence:
[A → B → A]
Torque - Front Caliper Mounting Bolts: 35 N·m (3.6 kgf·m,
26 ft·lb)

the brake lever.
• Release
Tighten
the
front caliper mounting bolts with the above
• torque and the
tightening sequence again.
the clearance [A] 0.5 mm (0.020 in.) or more be• Check
tween the caliper and disc at the lower position.
If there is no clearance, reinstall the caliper.

Rear Caliper Removal

• Remove:
Rear Wheel Rotation Sensor Bolt [A]
•
•
•

Rear Wheel Rotation Sensor [B]
Loosen the banjo bolt [C] and tighten it loosely to prevent
fluid spillage.
Loosen the caliper pin bolt [D].
Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).

12-16 BRAKES
Calipers
the banjo bolt and remove the brake hose from
• Unscrew
the caliper (see Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter).

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

NOTE

○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Rubber
Parts Replacement in the Periodic Maintenance chapter).

Rear Caliper Installation

silicone grease to the rear caliper pin bolt.
• Apply
Install
rear caliper to the bracket, and tighten the rear
• caliperthe
pin bolt temporarily.
the brake hose and rear wheel rotation sensor lead
• Run
correctly (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
○Avoid sharp bending, kinking, flatting or twisting.
Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).
Replace the washers that are on each side of hose fitting
with new ones.
Tighten:

•
•
•

Torque - Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

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

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.

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 12-17
Calipers
Rear Caliper Assembly

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

Caliper Fluid Seal Damage
The fluid seals (piston seals) [A] are 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 seals are replaced, replace the dust seals [B]
as well. Also, replace all seals every other time the pads
are changed.
Front Caliper [C]
Rear Caliper [D]

•

Rear Caliper Dust Boot and Friction Boot Damage

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.

12-18 BRAKES
Calipers
Caliper Piston and Cylinder Damage

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

Rear Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts [A]. 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 caliper holder shafts are not badly
worn or stepped, and that the rubber friction boots are not
damaged.
If the rubber friction boot is damaged, replace the rubber
friction boot. To replace the friction boot, remove the pads
and the caliper bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.

•

BRAKES 12-19
Brake Pads
Front Brake Pad Removal

the front caliper with the hose installed (see Front
• Remove
Caliper Removal).
• Remove:
Brake Pads [A]

Front Brake Pad Installation

the pad spring [A] on the caliper as shown.
• Install
the caliper pistons [B] in by hand as far as they will
• Push
go.
the brake pads on the pad spring correctly.
• Install
Install
the
front caliper (see Front Caliper Installation).
•

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

• Remove:
Pad Pin Plug [A]
Pad Pin [B]
Brake Pads [C]

12-20 BRAKES
Brake Pads
Rear Brake Pad Installation

that the pad spring is in place on the caliper.
• Check
the caliper piston in as far as it will go.
• Push
Install
piston side pad [A] first, and then another pad.
•○Fit thethe
brake pad end into the recess [B] of the caliper

•
•

holder.
Install the pad pin and the plug.
Tighten:
Torque - Rear Brake Pad Pin: 17.2 N·m (1.75 kgf·m, 12.7
ft·lb)
Rear Brake Pad Pin Plug: 2.5 N·m (0.25 kgf·m, 22
in·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 12-21
Master Cylinder
Front Master Cylinder Removal

• Remove:
Front Brake Fluid Reservoir Bracket Bolt [A]

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

NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely