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Disassembling the front brake
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CALIPER
NOTE:
Before disassembling the brake caliper, drain the brake fluid from the entire brake system.
• Remove:
union bolt 1
copper washers
brake hose 2
NOTE:
Put the end of the brake hose into a container and pump out the brake fluid carefully.
1 Remove:
brake caliper pistons 1
dust seals 2
brake caliper piston seals 3
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• Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper.
WARNING
Cover the brake caliper pistons with a rag. Be careful not to get injured when the pis-tons are expelled from the brake caliper.
Never try to pry out the brake caliper pis-tons.
b. Remove the dust seal and brake caliper pis-ton seals.
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EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain the brake fluid from the entire brake system.
4 - 51
FRONT AND REAR BRAKES CHAS
7) Remove:
nut 1
rear brake lock lever cable 2
pin 3
spring 4
union bolt 5
copper washers 6
brake hose 7
NOTE:
Put the end of the brake hose into a container and pump out the brake fluid carefully.
7) Remove:
brake caliper piston 1
dust seal 2
brake caliper piston seal 3
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• Turn the parking brake lever 4 continues until piston remove.
• Remove the dust seal and brake caliper pis-
ton seal.
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| EAS00631 | ||
| CHECKING THE FRONT AND REAR BRAKE | ||
| CALIPER | ||
| Recommended brake component | ||
| replacement schedule | ||
| Brake pads | If necessary | |
| Piston seals | Every two years | |
| Brake hoses | Every four years | |
| Every two years | ||
| Brake fluid | and whenever the | |
| brake is disassem- | ||
| bled. |
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4 - 52
| FRONT AND REAR BRAKES | CHAS | |||
| 1. Check: | ||||
| И | ||||
| • brake caliper pistons 1 | ||||
| Rust/scratches/wear → Replace the brake | ||||
| caliper. | ||||
| • brake caliper cylinders 2 | ||||
| Scratches/wear → Replace the brake cali- | ||||
| per. | ||||
| • brake caliper body 3 | ||||
| Cracks/damage → Replace the brake cali- | ||||
| per. | ||||
| • brake fluid delivery passages | ||||
| Й | ||||
| (brake caliper body) | ||||
| Obstruction → Blow out with compressed | ||||
air.
WARNING
Whenever a brake caliper is disassembled, replace the piston seals.
И Front
Й Rear
| И | 2. Check: |
• brake caliper bracket 1 Cracks/damage → Replace.
| И Front | |
| Й Rear |
Й
4 - 53
FRONT AND REAR BRAKES CHAS
EAS00635
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER
WARNING
a
• Before installation, all internal brake com-ponents should be cleaned and lubricated with clean or new brake fluid.
• Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
• Whenever a brake caliper is disassem-bled, replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
• brake caliper piston seals 1 New
• dust seals 2 New
• brake caliper pistons 3
9. Install:
brake caliper bracket
| T.R. | 40 Nm (4.0 m · kg, 2.9 ft · lb) |
8. Install:
brake caliper 1 (temporarily)
• copper washers New
9. brake hose 2
10. union bolt 3 
T. 30 Nm (3.0 m · kg, 22 ft · lb)
R.
WARNING
Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the brake caliper, make sure the brake pipe touches the projection a on the brake cali-per.
4 - 54
FRONT AND REAR BRAKES CHAS
10. Remove:
brake caliper
11. Install:
brake pad springs
brake pads
brake caliper
front brake caliper retaining bolts
T.
R.
27 Nm (2.7 m · kg, 19 ft · lb)
Refer to “REPLACING THE FRONT
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BRAKE PADS”.
10. Fill:
brake master cylinder reservoir
(with the specified amount of the recom-mended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
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