Brake lever/pedal soft or spongy

• Air in hydraulic system

• Leaking hydraulic system

• Contaminated brake pad/disc

• Worn caliper piston seal

• Worn master cylinder piston cups

• Worn brake pad/disc

• Contaminated caliper

• Contaminated master cylinder

• Caliper not sliding properly

• Low brake fluid level

• Clogged fluid passage

• Warped/deformed brake disc

• Sticking/worn caliper piston

• Sticking/worn master cylinder piston

• Bent brake lever/pedal

 

Brake lever/pedal hard

• Clogged/restricted brake system

• Sticking/worn caliper piston

• Sticking/worn master cylinder piston

• Caliper not sliding properly

• Warped/deformed brake disc

• Bent brake lever/pedal

 

Brake drags

• Contaminated brake pad/disc

• Misaligned wheel

• Badly worn brake pad/disc

• Warped/deformed brake disc

• Caliper not sliding properly

• Clogged/restricted fluid passage

• Sticking caliper piston

 

 

18-2

BRAKE SYSTEM

COMPONENT LOCATION

 

FRONT:

 

1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

 

30 N·m (3.1 kgf·m, 22 lbf·ft)

 

34 N·m (3.5 kgf·m, 25 lbf·ft)

 

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

 

 

34 N·m (3.5 kgf·m, 25 lbf·ft)

 

REAR:

1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

 

34 N·m (3.5 kgf·m, 25 lbf·ft)

 

 

34 N·m (3.5 kgf·m, 25 lbf·ft)

 

 

14 N·m (1.4 kgf·m, 10 lbf·ft)

 

10 N·m (1.0 kgf·m, 7 lbf·ft)

 

 

18-3

BRAKE SYSTEM

BRAKE FLUID REPLACEMENT/AIR

BLEEDING

 

BRAKE FLUID DRAINING

 

For front brake: Turn the handlebar until the master cylinder reservoir is
		[2]
[1]
level before removing the reservoir cap.
		[3]
Remove the screws [1], reservoir cap [2], set plate [3],

and diaphragm [4].

 

[4]

 

For rear brake: Remove the bolt [1] and reservoir [2].

 

Remove the cover screws [3], reservoir cover [4], set plate [5] and diaphragm [6].

 

Connect a bleed hose [1] to the bleed valve [2].

 

Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve. Tighten the bleed valve.

 

TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

 

 

		[3]
[1]

 

 

[2] [4]/[5]/[6]

 

 

[2]

 

 

[1]

 

 

Check the fluid level often while bleeding the brake to prevent air from being pumped into the system.

 

BRAKE FLUID FILLING/AIR BLEEDING

 

Close the bleed valve.

 

Fill the reservoir to the upper level line [1] with DOT 3 or DOT 4 brake fluid from a sealed container.

 

Connect a commercially available brake bleeder to the bleed valve.

 

Operate the brake bleeder and loosen the bleed valve.

 

If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low.

 

Perform the bleeding procedure until the system is completely flushed/bled.

 

Close the bleed valve and operate the brake lever or pedal. If it still feels spongy, bleed the system again.

 

FRONT: REAR:

[1]
	[1]

 

18-4

BRAKE SYSTEM

 

Do not release the lever or pedal until the bleed valve has been closed.

 

 

For rear brake:

 

If a brake bleeder is not available, use the following procedure:

 

Connect a bleed hose to the bleed valve.

 

Pressurize the system with the brake lever or pedal until lever or pedal resistance is felt.

 

1. Squeeze the brake lever or depress the brake pedal, open the bleed valve 1/4 turn and then close it.

 

2. Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel.

 

3. Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose.

 

After bleeding the system completely, tighten the bleed valve to the specified torque.

 

TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

 

Fill the reservoir to the upper level line with DOT 3 or DOT 4 brake fluid.

 

Install the diaphragm, set plate and reservoir cover and tighten the screws to the specified torque.

 

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

Install the reservoir and bolt, then tighten it to the specified torque while pushing the reservoir against the stopper.

 

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

 

BRAKE PAD/DISC

 

FRONT BRAKE PAD REMOVAL/

INSTALLATION

 

Remove the pad pin [1].

 

			[1]
Pull the pad pin out of the caliper body while pushing in
the pads against the pad spring.					Align
Align
Remove the brake pads [1].

Install the brake pads into the caliper so their ends rest into the pad retainer on the bracket properly.

 

[1]

 

18-5

BRAKE SYSTEM

 

Make sure the pad spring is installed correctly.

 

Always replace the brake pads in pairs to ensure even disc pressure.

 

Apply silicone grease to a new stopper ring [1] and install it into the pad pin [2] groove.

 

Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body.

 

Tighten the pad pin to the specified torque.

 

TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft)

 

Operate the brake lever to seat the caliper pistons against the pads.

 

 

[1]

 

[2]

 

Make sure the pad spring is installed correctly.

 

Always replace the brake pads in pairs to ensure even disc pressure.

 

REAR BRAKE PAD REMOVAL/

INSTALLATION

 

Remove the pad pin plug [1] and pad pin [2].

 

Remove the brake pads [3].

 

[1]

 

Apply silicone grease to a new stopper ring [1] and install it into the pad pin [2] groove.

 

Install the brake pads [3] into the caliper.

 

Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body.

 

Tighten the pad pin to the specified torque.

 

TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft)

 

Install the pad pin plug [4].

 

Operate the brake pedal to seat the caliper pistons

against the pads. [3]

 

 

[2]

 

[3]

 

 

[1]

 

 

[2]

 

[4]

 

 

BRAKE DISC INSPECTION

 

Visually inspect the brake disc for damage or cracks.

 

Measure the brake disc according to BRAKE SYSTEM SPECIFICATIONS (page 1-8) and replace if necessary.

 

 

18-6

BRAKE SYSTEM

 

FRONT MASTER CYLINDER

 

REMOVAL/INSTALLATION

 

Drain the brake fluid from the front brake hydraulic system (page 18-4).

 

Remove the following:

 

When removing the	– Right rearview mirror [1]
oil bolt, cover the	–	Oil bolt [2]
end of the hose to	–	Sealing washers [3]
prevent	–	Brake hose [4]

contamination. – Brake light switch connectors [5]

 

 

– Bolts [1]

– Master cylinder holder [2]

– Master cylinder [3]

 

Installation is in the reverse order of removal.

 

• Replace the sealing washers with new ones.

• Align the edge of the master cylinder with the punch mark on the handlebar.

 

• Install the master cylinder and holder with its "UP" mark [4] facing up.

 

• Tighten the upper bolt first, then tighten the lower bolt.

 

TORQUE:

 

Front master cylinder holder bolt: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

 

Oil bolt:

 

34 N·m (3.5 kgf·m, 25 lbf·ft)

 

Fill and bleed the hydraulic system (page 18-4).

 

 

		[4]
[1]

 

 

[5]

[3]

[2]

[2]

Align

[3]

 

 

[4]	[1]

 

18-7

BRAKE SYSTEM

DISASSEMBLY/ASSEMBLY

 

Disassemble and assemble the front brake master cylinder as following illustration.

 

• Replace the master piston, spring, piston cups and snap ring as a set.

 

• Do not allow the piston cup lips to turn inside out.

• Be certain the snap ring is firmly seated in the groove.

				PIVOT BOLT
						Align
BOOT
		1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
					MASTER
						SEPARATOR
					PISTON

 

SNAP RING	SPRING

 

			PISTON		STOPPER RING
			CUPS

 

 

BRAKE LEVER

 

									MASTER CYLINDER
			PIVOT NUT
						BRAKE LIGHT SWITCH
				SCREW
			5.9 N·m (0.6 kgf·m,
DUST COVER
			1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
		4.4 lbf·ft)

 

INSPECTION

 

Check the following parts for scoring, scratches, deterioration or damage.

 

– Master cylinder

– Master piston

– Piston cups

– Spring

– Boot

 

Measure the parts according to BRAKE SYSTEM

SPECIFICATIONS (page 1-8) and replace if necessary.

 

REAR MASTER CYLINDER

 

 

When removing the oil bolt, cover the end of the hose to prevent contamination.

 

REMOVAL/INSTALLATION

 

Drain the brake fluid from the rear brake hydraulic
		[3]
system (page 18-4).
[2]
Release the reservoir hose [1] from the clamp [2].				[4]
Remove the following:
–	Oil bolt [3]
–	Sealing washers [4]
–	Brake hose

 

 

[1]

 

18-8

BRAKE SYSTEM

 

– Cotter pin [1]

– Joint pin [2]

– Master cylinder mounting bolts [3]

 

 

– Snap ring [1]

– Hose joint [2]

– O-ring [3]

– Rear master cylinder [4]

 

Installation is in the reverse order of removal.

 

• Replace the O-ring, master cylinder mounting bolts, cotter pin and sealing washers with new ones.

• Apply brake fluid to the joint O-ring.

 

TORQUE:

 

Rear master cylinder mounting bolt: 14 N·m (1.4 kgf·m, 10 lbf·ft)

 

Oil bolt:

 

34 N·m (3.5 kgf·m, 25 lbf·ft)

 

Fill and bleed the hydraulic system (page 18-4).

 

DISASSEMBLY/ASSEMBLY

 

Disassemble and assemble the rear brake master cylinder as following illustration.

 

 

			[3]
	[1]

 

 

[2]

 

[2]

 

				[3]
		[4]
[1]

 

• Replace the master piston, spring, piston cups and snap ring as a set.

 

• Do not allow the piston cup lips to turn inside out.

• Be certain the snap ring is firmly seated in the groove.

 

Standard push rod length:

 

64 - 65 mm

 

(2.52 - 2.56 in)

MASTER CYLINDER

 

MASTER PISTON

 

 

SNAP RING

BOOT

SPRING

PISTON CUPS

PUSH ROD LOCK NUT

17.2 N·m (1.8 kgf·m, 13 lbf·ft)

BRAKE ROD JOINT

PUSH ROD ASSEMBLY

 

 

18-9

BRAKE SYSTEM

INSPECTION

 

Check the following parts for scoring, scratches, deterioration or damage.

 

– Master cylinder

– Master piston

– Piston cups

– Spring

 

Measure the parts according to BRAKE SYSTEM

 

SPECIFICATIONS (page 1-8) and replace if necessary.

 

FRONT BRAKE CALIPER

 

REMOVAL/INSTALLATION

 

When removing the oil bolt, cover the end of the hose to prevent contamination.

 

 

Drain the brake fluid from the front brake hydraulic
	[4]
system (page 18-4).
Remove the following:
–	Oil bolt [1]
–	Sealing washers [2]
–	Brake hose [3]
–	Brake caliper mounting bolts [4]
–	Brake caliper [5]
Installation is in the reverse order of removal.
•	Replace the brake caliper mounting bolts and
	sealing washers with new ones.

 

TORQUE:
[5]
Brake caliper mounting bolt:
30 N·m (3.1 kgf·m, 22 lbf·ft)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)

 

Fill and bleed the hydraulic system (page 18-4).

 

DISASSEMBLY/ASSEMBLY

 

[3]

 

 

			[1]
	[2]

 

Disassemble and assemble the front brake caliper as following illustration.

BRACKET PIN BOOT

 

CALIPER PISTONS

CALIPER BRACKET

 

DUST SEALS

 

PISTON SEALS

 

 

BRACKET PIN

 

17.2 N·m (1.8 kgf·m, 13 lbf·ft)

 

BRACKET PIN BOOT

 

BRAKE PADS	PAD SPRING

 

 

BLEED VALVE

 

5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

 

 

CALIPER BODY

 

 

STOPPER RING

 

PAD PIN

 

17.2 N·m (1.8 kgf·m, 13 lbf·ft)

 

 

18-10

BRAKE SYSTEM

INSPECTION

 

Check the following parts for scoring, scratches, deterioration or damage.

 

– Caliper cylinders

– Caliper pistons

 

Measure the parts according to BRAKE SYSTEM

 

SPECIFICATIONS (page 1-8) and replace if necessary.

 

REAR BRAKE CALIPER

 

 

When removing the oil bolt, cover the end of the hose to prevent contamination.

 

REMOVAL/INSTALLATION

 

Drain the brake fluid from the rear brake hydraulic system (page 18-4).

 

Remove the oil bolt [1], sealing washers [2], and brake hose [3].

 

Remove the rear wheel (page 17-4).

 

Remove the rear brake caliper [1] from the slide rail [2] of swingarm.

 

Installation is in the reverse order of removal.

 

• Replace the sealing washers with new ones.

 

TORQUE:

 

Oil bolt: 34 N·m (3.5 kgf·m, 25 lbf·ft)

 

Fill and bleed the hydraulic system (page 18-4).

 

	[2]
		[1]

 

[3]

 

 

[2]
	[1]

 

18-11

BRAKE SYSTEM

DISASSEMBLY/ASSEMBLY

 

Disassemble and assemble the rear brake caliper as following illustration.

 

RETAINER

 

BRACKET PIN

BOOT

DUST SEAL

PISTON

SEAL

BLEED VALVE

5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

CALIPER BODY

STOPPER

RING

CALIPER BRACKET

PAD PIN

17.2 N·m (1.8 kgf·m,

BRAKE PADS

13 lbf·ft)

 

	CALIPER PISTON
		PAD SPRING
			BRACKET
						PAD PIN PLUG
					PIN BOOT

 

INSPECTION

 

Check the following parts for scoring, scratches, deterioration or damage.

 

– Caliper cylinder

– Caliper piston

 

Measure the parts according to BRAKE SYSTEM

SPECIFICATIONS (page 1-8) and replace if necessary.

 

BRAKE PEDAL

 

REMOVAL/INSTALLATION

 

Remove the following:

– Brake light switch return spring [1]

– Brake pedal return spring [2]

 

[1]

[2]

 

18-12

BRAKE SYSTEM

 

– Cotter pin [1]

– Joint pin [2]

– Brake rod joint [3]

– Stopper pin [4]

– Washer [5]

 

 

– Brake pedal [1]

– Dust seals [2]

 

Installation is in the reverse order of removal.

 

• Replace the dust seals and cotter pin with new ones.

 

• Install the dust seals in shown direction.

• Apply grease to the brake pedal pivot sliding surface and dust seal lips.

 

[4]
[5]			[1]

 

[2]

 

[3]

 

[2]

 

 

[1]

 

[2]

 

[1]

 

 

18-13

MEMO

BATTERY/CHARGING SYSTEM

 

SERVICE INFORMATION···························19-2

 

TROUBLESHOOTING·································19-2

 

SYSTEM LOCATION···································19-3

 

SYSTEM DIAGRAM ····································19-3

 

BATTERY····················································19-4 CHARGING SYSTEM INSPECTION ··········19-4 ALTERNATOR CHARGING COIL··············19-5 REGULATOR/RECTIFIER ··························19-6

 

 

19-1

BATTERY/CHARGING SYSTEM

SERVICE INFORMATION

 

GENERAL

 

• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.

• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

 

– If electrolyte gets on your skin, flush with water.

– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.

• Electrolyte is poisonous.

– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.

 

• Always turn OFF the ignition switch before disconnecting any electrical component.

• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present.

• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge the stored battery every 2 weeks.

 

• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.

• The maintenance free battery must be replaced when it reaches the end of its service life.

• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same conditions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2

– 3 years.

• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one