A The minimum disc thickness is marked on the disc

B Measuring the disc thickness

4.5 Unscrew the disc retaining bolts ina criss-cross pattern

greater than the service limit, check the wheel bearings (or play (see Chapter 1). If the bearings are worn, renew them (see Section 17) and repeat this check. If the disc runout is still excessive, the disc will have to be renewed, although machining by an engineer may be possible.

3 The disc must not be machined or allowed
to wear down to a thickness less than the
service limit listed in this Chapter's
Specifications and as marked on the disc
itself (see illustration).The thickness of the
disc can be checked with a micrometer
(see illustration).If the thickness of the disc
is less than the service limit, it must be
renewed.

Removal

4 Remove the front wheel (see Section 15). Caution: Do not lay the wheel down and allow it to rest on the disc - the disc could become warped.

Installation

6 Place the disc on the hub, making sure the marked side is on the outside. Align the previously applied reference marks if reinstalling the original disc.

7Install the new bolts, and tighten them in a criss-cross pattern evenly and progressively to the torque setting specified at the beginning of this Chapter. Note that the new bolts are supplied with a dry coating of locking compound on their threads.

8 Clean all grease off the brake disc using acetone or brake system cleaner. If a new brake disc has been installed, remove any protective coating from its working surfaces.

9 Install the wheel (see Section 15).

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

5 Front brakemaster cylinder

- removal, overhaul and ^»

installation ^

1 If the brake lever does not feel firm when the brake is applied, and the hydraulic hose is in good condition and bleeding the brake does not help (see Section 11), orif the master cylinder is leaking fluid, then master cylinder overhaul is recommended.

2 Before disassembling the master cylinder, read through the entire procedure and make sure that you have obtained all the new parts required including some new DOT 4 brake fluid, some clean rags and internal circlip pliers. Note:If the master cylinder is just being displaced and not completely removed from the motorcycle, do not remove the front brake

lever or the brake light switch or disconnect the brake hose..

Caution: Disassembly, overhaul and reassembly of the brake master cylinder must be done in a spotlessly clean work area to avoid contamination and possible failure of the brake hydraulic system components. To prevent damage to the paint from spilled brake fluid, always cover the fuel tank when working on the master cylinder.

Removal

3Lift the cover, where fitted, on the rear view mirror mounting locknut, slacken the locknut and unscrew the mirror.

4 Disconnect the wiring connectors from the brake light switch (see illustration).If necessary, remove the screw securing the brake light switch to the bottom of the master cylinder and remove the switch.

5 Remove the front brake lever (see Chapter 6, Section 5).

6 Unscrew the brake hose banjo bolt and separate the hose from the master cylinder, noting its alignment (see illustration).Discard the sealing washers as they must be renewed. Wrap a plastic bag tightly around the end of the hose to stop dirt entering the system and secure the hose in an upright position to prevent fluid spills.

7 Unscrew the master cylinder clamp bolts, remove the clamp, then lift the master cylinder away from the handlebar (see illustration).

8Unscrew the reservoir cover retaining screws and lift off the cover, the diaphragm

Date: 2016-01-14; view: 564