If the pads have worn to or beyond the

Wear limit cutout (arrowed) they must be

Renewed

(see illustration). Due to the Increased friction material thickness of new pads, It may be necessary to remove the master cylinder reservoir cover and diaphragm and remove some fluid.

7 Smear the backs of the pads and the shank of the pad pin with copper-based grease, making sure that none gets on the front or sides of the pads.

8 Installation of the pads is the reverse of removal. Make surethe pad spring is correctly positioned in the caliper mouth and the pad plate Is in place on the caliper bracket. Insert the pads into the caliper so that the friction material faces the disc, making sure they locate correctly against the pad spring and pad plate, then push up on the pads to align the holes and slide the pad retaining pin through (see illustrations and 2.1b). Make

Push the caliper against the pad to create the extra room

A Install the pads.

B... making sure they locate correctly in the pad plate on the bracket (arrowed)

7»4 Brakes, wheels and tyres

Note the alignment of the hose before removing the banjo bolt (arrowed)

sure the pin passes through the hole in each pad. Tighten the pad retaining pin to the torque setting specified at the beginning of the Chapter. Install the pad pin plug and tighten It to the specified torque (see illustration 2.1a).

9 Top up the master cylinder reservoir if
necessary (see Daily (рге-ride) checks), and
refit the reservoir cover and diaphragm.

10 Operate the brake lever several times to
bring the pads into contact with the disc.
Check the operation of the brake before riding
the motorcycle.

I

3 Front brake calipers -

removal, overhaul and installation

3.3a Unscrew the caliper mounting bolts (arrowed)...

overhaul the caliper and don't have a source of compressed air to blow out the pistons, just loosen the banjo bolt at this stage and retighten it lightly. The bike's hydraulic system can then be used to force the pistons out of the body once the pads have been removed. Disconnect the hose once the pistons have been sufficiently displaced.

3 Unscrew the caliper mounting bolts, and
slide the caliper off the disc (see
illustrations).

Overhaul

4 Slide the caliper off the caliper bracket,
noting how it fits (see illustration). Remove
the pad plate on the caliper bracket and the
pad spring inside the caliper mouth, noting
how they fit. Clean the exterior of the caliper
with denatured alcohol or brake system

3.3b... and slide the caliper off the disc

cleaner. Make sure all old grease is removed from the slider pins.

5 Displace the pistons as far as possible from the caliper body, either by pumping them out by operating the front brake lever, or by forcing them out using compressed air. If the compressed air method is used, place a wad of rag between the pistons and the caliper to act as a cushion, then use compressed air directed into the fluid inlet to force the pistons out of the body. Use only low pressure to ease the pistons out and make sure both pistons are displaced at the same time. If the air pressure is too high and the pistons are forced out, the caliper and/or pistons may be damaged. Mark each oiston head and caliper bore with a felt marker to ensure that the pistons can be matched to their original bores on reassembly.

11 12 13 14 15

A

Warning: If a caliper indicates the need for an overhaul (usually due to leaking fluid or sticky operation), all old brake fluid should be flushed from the system. Also, the dust created by the brake system may contain asbestos, which is harmful to your health. Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use clean brake fluid, brake cleaner or denatured alcohol only.

Removal

1 If the calipers are being overhauled, remove the brake pads (see Section 2). If the calipers are just being displaced or removed, the pads can be left in place.

2 If the calipers are just being displaced and not completely removed or overhauled, do not disconnect the brake hose. If the calipers are being overhauled, note the alignment of the brake hose on the caliper then unscrew the brake hose banjo bolt and separate the hose from the caliper (see illustration). Plug the hose end or wrap a plastic bag tightly around it to minimise fluid loss and prevent dirt entering the system. Discard the sealing washers as new ones must be used on installation. Note: If you are planning to

1 Pad retaining pin plug

2 Pad retaining pin

3 Brake pads

4 Bleed valve

5 Bleed valve cap

Дата добавления: 2015-10-29