Honda Cbr150r 2002-2009

Remmoovvee the oiill seaall fromm the fork slideerr.. FRONNTT WHEEL/SUSPENSIONN/SSTTEEEERRIlNNGG

OIL. SEAL RE MOVE R

TOOLL:: 077774488-000011000001
Oill seal remover

INSPPEECCTTIIOONN

Forkk Spring
Measure the fork spring free length.
SERVIICCEE LIIMMIITT::404.11 mm (1155..9911inn))

Forkk Pipe/Slider/Pistonn FORK PISTON aRK PIPE

Checkk the fork pipe, slider andd pistoonn for scoree marks, /
scratcchheess,, or excessivvee or abnormal wear.
Checkk the rebouunndd spring for damage.
Checkk the piston ringg for wear or damagee..

Reppllaaccee any components that are worn or damage.

REBOU D FORK SLIDER
SPRING

Set the fork pipe inn V-blocks andd reaadd the runout with a I

dial indicator.
SERVVIICCEE LLIIMMIITT::00.20 mmmm (0.000088 inn))
Thee actuuaall runout iss 1/2 of the totall indicator reading.

http://www.motorcycle.in.th 14-15

FRONT WWHHEEEELL//SUSSPPEENNSSIIOON//SSTTEEEERRIlNNGG

ASSEEMMBBLLY

DUST SEAL FORK PIPEE FORK, BOLLTT
\y . ,\ Oa--RRING
7 SSPPRRIINNGG SSEEAATT

\

FORK PISTON

PISTON RING

~tIt 4 \

SEAALLIINNGG WAASSHER RREEBBOOUUNNDD SSPPRRIINNGG FORK SPRINNGG

OIL LOCK PIECE

Beffoorree assembllyy, washh alll parrttss with a hiigghh fllasshh poinnttor OIL Lor PIECE:
noonn-ffllaammmmaabbllee solvent and wippe them off commppllettely.

Inssttaalllthhe oiill loocckk piieeccee and fork tubbe inttoo thhe forrkk slliiddeerr..

~/
ORK PIP

Innssttaalll thhe ffoorrkk ppiissttoonn andd rrebboouunndd sspprriinngg iinnttoo tthhe ffoorrkk
ppiippee..

1144--1166 ORK PI S O N

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FRONT WHEEL/SUSPENSION/STEERlING

Cleaann and apply a locking agent to the fork socket bolt rO:R K SLI DE R .SOCK£fBOI.I
threads.
Installll a new sealing washer and socket bolt.

Hold the fork slider inn a vise with piece of woods or shop
towel.
lTigighhten the fork socket bolt to the specified torque.

TORRQQUUEE: 20 N·m (2..00 kg9f·.m., 14 I1bbff..fftt))

NOTEE::

If the socket bolt turn together with the fork piston, tem-
porarily install the fork spring and fork bolt.

Apply fork fluid to the lip of the oil seal. OOI VEfI
Drive the oil seal using the oil seal driver.

rToOoOLLSs:: -0774477-00001100110000

Fork seall driver 07747 - 0010300

Fork seall driver attachment

Installl the oil seal stopper ring into the groove of the fork DUST SEAL
slider.
Installll the dust seal.

STOPf'EfI RING --=--------=-----=-

Compress the fork pipe all the way and pour inn the speci- 14-17
fied amount of fork fluid.
OIL CAPPAACCITITYY:

*206 k±2.5 ecm’' (7.00 k±0.08 US 0O2Z,.77..33 ±0.09 Imp 0O2Z)

Pump the fork pipe slowly several times to stabilize the
fork oil level.
Compress the fork all the way and measure the oil levell
from the top of the pipe.
OIL LEVELl: 13311 mm (5.2 inn))

http://www.motorcycle.in.th

FROONNTT WHEEL/SUSPENSION/STEERIlNG

Wipe oill offf the spring thoroughly usinngg a cleann cloth..
Install the fork spring with the tightly wound endd facing
down.

..

Inssttaalll the spring seat andd spring collar. SPRING eQUAl'!:

Apply fork fluidd to a new O-ring.
Insttaallll a new O-rinngg onto the fork bolt andd instaallll it loosely.

NOOTE::

Inssttaalll the fork bolt but do not tigahten yvet.

INSTTAALLLLAATTIIOONN

Insttaalll the fork legg andd temporarily tighten the fork bot--
tomm pincchh bolt.

Inssttaalll the following: ttA!NOuEBAft
-hahnadnldelbeabrasrs (paaggee 14-5)1
\,
Loosseenn the handlebar pincchh bolt.
Loosseenn the fork bottom pincchh bolt andd align the stopper
ringg groove with upper surface of the handlebar.

14-188 http://www.motorcycle.in.th

FFRROONNTT WWHHEEEELL//SSUUSSPPEENNSSIIOONN//SSTTEEEERRIlNNGG

Tighten thee fork bboottttoomm ppiinncchh bboollttsstoo thhee ssppeecciiffiedd torque.
TORRQQUUEE: 26 NN·mm (22..77 kkggff·m, 20 Ibbff..fftt))
TXightenn the fork top pinncchh bolt too the specciiffiieedd torque.
TORQUE:: 23 NN·mm (22..33kkggff·m, 177 Ibf4.f-tt)

Tighten the fork bolt to the specified torque.
TORQUE:: 2233 NN'mm (22..33 kkggff·m,, 1177 Ibbff·4ttt))
Tighten the handlebar pinncchh bolltt..
TORRQQUUEE: 27 NN·.rmn (22..88kkggff·m, 220 Ibbff·4ttt))

Inssttaallll the following::
-frofrnotnt fender (paggee 2-3)
-frofrnotnt wheel (paggee 14-122))
-brbarkaeke cariper (pagee 166--1199))

STEERINNGG STEMM

REMOVALL

Removee the following:

--handlebars (page 14-3))

-upuppeprer cowl (pagee 2-4)
-frofrnotnt wheel (paggee 14-8))
-frofrnotnt fender (pagee 2-3)

Remove the steering stem nut and washeerr.
Removee the fork (page 14-12).
Removee the top bridge..

Remoovvee the horn stay mounting bolts and hornn stay.

HORN STAY 14-19
http://www.motorcycle.in.th

FRONNTT WHEELL/SUSSPPEENNSSIIOONN//SSTTEEEERRIlNNGG

Removvee the top thread using the special tool.

TOOOLL: -0791166- 371100110011 STEERI {j
Steerinngg stem socckket
STE soc ET

Remove the following:
-totpop cone racee
-upuppeprer bearing
-stesteereinrigng stem

--lolowweerr bearing

CAUTIIOONN::

Bee carefull not to lose any of the beariinngg..

BEARIING RACE REPLLACEMENT

NOTE::
Replaacceethe bearing and raceess as a set.

Remove the balll raceess using the special tool.

TOOOLL: -07GMMDD - KKSS4400110000
Balll raccee removverr

Instaallll the new ball raceess usingg the speciaall tools.

TOOLS:: -0774499 - 0011O00O0W0
Drivver
Attachment, 42 x 47 mmm 07774466-00001100330000

14-20 http://www.motorcycle.in.th

BOonTTOOMM CONEE RAACCEE REPLLAACCEEMMEENNTT FRROONNTT WHEEELL//SSUUSSPPEENNSSIIOONN//SSTTEEEERRIlNNGG

Avoid damagingg the steering stemm thread, temporarily STH. UT
instaallll the stemm nut..
Removee the bottom cone race, dust seaall and dust seaall
washer.

BonOM CONE M ,O J
DU ST SEAlJWASH R

Instaallll the new dust seall and bottom cone racee.. STEERING
STE DRIVER
Drive a new bottom cone racee onto the steering stem us--

ing the special tool.

TOOL:: Q071994466--4430000110Q11
Steering stem drriver

INSTALLLAATTIIOONN

6-liiiiiit BOlTOM BBALL RAC~E TOP THREAADD
BOTTOM ~AAlNGTOP CONE RACE

LLOOWWEERABBEEAAAR'INNGG ~ TOPCO\i

BOTTOM CONE RACE ~LlAACE

~

STEERING STEM

STAY

http://www.motorcycle.in.th 14-2211

FRONTT WHEEL/SUSPENSION/STEERlING

Apply greasee to all bearing area.
Instaalll the lower bearinngg..
Instaalll the steeringg stem, upper bearing and top cone race..

CAUUTTIIOONN:.
Be careful not to losse any of the beariinngg..

Installll the top thread.
TIighten the top threadd to the initial torque usingg the sppee-
ciaall tool while holding steerinngg stem securely.

TOOOOLL: 077991166-3377110011001
Steeeerriing sstteemm ssoocket

TOORRQQUUEE: 277 NN'mm (22..B8 kggff·mm, 200 Ibbff.4ftt))

Move the steerinngg stemm right andd left, lock-to-Ilock, five
times for racceess andd bearriinnggss to get to fit enougghh..
Loosseenn the top threadd compleetteellyy..

Reettigghhtteenn the topp threeaadd too the speecciiffiieedd torquee ussiinngg the
specciiaall tool.

TOOOOLL: 0077991166-337711001101
SStteeeerriing sstteemm ssoocckkeett

TOORRQQUUEE:: 11..00 NN'mm ((00..11 kkggff·mm, 00..77 Ibbff·4ftt))

144--2222 http://www.motorcycle.in.th

FRONNTT WHEEL/SUSPEENNSSIOONN/STTEEEERRIlNNGG

Installll the horn stay.

Installl the following:
-- ttoopp bridge
- frofrnotnt fork (paaggee 14-1188))
-wwaasshherer

--stemm nut

TIightenn the stem nut to the specciiffiieedd torque.

TORRQQUUEE: 88 NN·.mm (99 kkggff·.mm, 655 Ibf·4tt)l

Instaallll the following:
-frofrnotnt fender (paggee 2-31)
-ffrroonnt t wheeell (paggee 14-1122))
-hahnadnledlbeabrar (page 14-5)

--upper cowl (paaggee 2-51)

STEERINNGG BEAARRIINNGG PRELOOAADD I

Raissee the front wheel off the ground.
Possiittiioonn the steeringg stemm to the straight ahead position.
Hook a spring scallee to the fork pipe betwweeeenn the fork top
and bottom bridges.
Makkee sure that there is noo cable or wire harneessss interfer--
ence.
Pullll the spring scale keepinngg the scalee at a rightt angle to
the steerriinngg stem.

Reeaadd the scalee at the point where the steering stemm just
starrttss to moovvee..

STEERINNGG BBEEAARRIINNGG PPRREELLOOAADD::

- -00.100 - 00..1155 kkggtf ((00..222200- 00..333300 IIbbtf)l

If thee reaaddiinnggss doo nott faallll withiinn the limits, reeaaddjjuusstt the
steeeerriinngg top thread.

Inssttaallll thee remmoovveedd partss inn the reveerrssee order of remmoovvaall..

http://www.motorcycle.in.th 144-2233

REARR WHEEL/SUSPENSSIONN

3399 NN·mm (4.0 kggff·m., 29 (Ibf.ft))

88 N m (9.0kgfm, 65 Ibf.ft)

44 NN·m (4.5 kgf·m.
33 (bf·ft)

15--00 http://www.motorcycle.in.th

15. REARR WHEEUSUUSSPPEENNSSIIOONN

SSEERRVVIICCEE IINNFORMMAATTIIOONN 1155--11 SHOCKK AABBSSOORRBBEERR 1155--99
TTRROOUUBBLLEESSHHOOOOTTIINNGG 1155--22 SWWINNGGAARRMM 1155--1100
RREEAARR WWHHEEEELL 1155--33

SERVICE INFOORRMMAATTIIOONN

GENERAALL

'¥lMM;

• AA ccoonnttaammiinnated bbrraakke ddiisscc oor pad rreedduucceess ssttooppppiinngg ppoowweerr, DDiissccardd ccoonnttammiinnated ppads and cclleeann ccoonnttaammiinnated
ddiisscc wwiitthh aa hhiigghh qquuality bbrraakkee ddeeggrreeaassiinnggaggeenntt..

• WWhheeeellbbaallannccee ddiirreccttllyy afffecttss tthhee ssttaabbiilliittyy,, hhanddlliinngg and oovveerrall ssafety of tthhee mmoottoorrccyyccllee.. CCarefullyy cchheck bbaallaannccee
bbeeffoorre rreeiinnssttaalllliinngg tthhee wwhheeeell..

CAAUUTTIIOONN::
TToo avoid ddaammaaggiinngg tthhee rriimm wwhheenn uussiinngg tthhee ttiirree lleevveerr,, alwways uussee rriimm pprrootteeccttoorrss..

* When servicing the rear wheel, swingarm or shock absorber, support the motorcycle securely usingg a hoist or
equivalent.
Usee only genuinee Honnddaa replacement bolts and nuts for all suspeennssiioonn pivot and mounting pointss..

SPECIFICCAATTIIOONNSS

ITEEMM STAANNDDAARRDD Unit: mmm (iinn))

Minimum tire tread depth --- SERVICE LLIIMMIITT

Coldd tire pressure I Driver only 200 kPPaa (2.0000 kgf/cm2',,29 pssii)) To the indicator

I Driver and passenger 225 kPa (2.25 kgf/ccmm2',,33 pssii)) ---
---
Axle runout ---
--- 0.20 (0.00088))
Wheel rim runout I Radial 2.0 (0.088))
--- 2.0 (0.088))
- IWheel balancer weight Axial --- 60 g9 (2.11 0o2z)) max.

Drive chain II Size/llink DID42288VV1133--112244LLEE ---

I I Slack I2255--3535(1(.10.0-1-1.4.4) ) --- 1

TORQUE VALUES

Rear axle nut 59 N.·m (6..00 kgff·m, 43 Ibf·.ft) U-nut
Driven sprockkeett nut 64 N.·mm (6.5 kgff.mm, 47 Ibf.·ftt)) U-nut
Rear brake disc bolt 42 N.·mm (4.3 kgff·mm, 311 Ibf.·ft) ALOC bolt
Shock absorber upper mounting bolt 39 N·m (4.00 kgff.mm, 29 Ibf.·ft)
Shock absorber lower mounting nut 44 N·m (4.5 kgf.·mm,, 33 Ibf.·ft)) U-nut
Swingarm pivot nut 88 N.·m (9.0 kgf.·mm,, 65 Ibff·Wft) U-nut
Chain slider screw 5.9 N.·mm (0.6 kgf.·m, 4.3 Ibff·Wft)

http://www.motorcycle.in.th 15--11

REARR WHEEL/SUSSPPEENNSSIIOONN 077774466-0005500330000
07774466-0005500110000
TOOLSS 07774499-0001100000000
07774466-0001100220000
Bearinngg remover head, 1122 mmm 077774466-0004400220000
Bearinngg remover shaft
Driver
Attachment, 377 x 40 mmm
Pilot, 122 mmm

TROUBLESHOOTINNGG

WWoobbble or vibration inn motorcyclee

--* Bentt rimm
Beennttspokess
Damaaggeedd tire
Axle not tightened properly
* Chaaiinn adjusters not adjusted equally

SSoofft suspeennssiioonn
Weeaakkspring
Oill leakaaggee fromm damper unit

* lTiriree pressure too low

-HHaarrdd suspeennssiioonn
Bent damper roodd
* Bent frame or swing armm
* lTiriree pressure too highh

SSuussppeennssiioonn noisee
Faulty damper

•* Loossee fasteners

-Steeers to one side or does not treck straight
Reenntt rear axlee
•* Axle alignmenntv/chain adjustment not equuaall bothh sides

15-22 http://www.motorcycle.in.th

REARR WHEEL/SUSPENSION

REAR WHEEL

REMOVVAALL

Support the motorcycle securely usingg a hoist or equiva--
lentt..

Loosseenn the drive chaiinn adjusting nuts andd lock nuts.

Loosseenn the rear axle nut.
Puusshh the rear wheel forward.
Deraaiill the drive chain.

Remoovvee the axle nut.
Remoovvee the rear axlee fromm the right side.
Remoovvee the rear wheel and side collars.

INSPEECCTTIIOONN

Axle
Plaaccee the axlee inn V-blocckkss andd measure the runouutt..
Actual runout is 1/2 the total indicator reading.

SERRVVIICCEELIIMMITIT: 0.20 mmmm (0.000088 iinn))

Wheel rimm runoutt

Checkk the rimm runout by placing the wheel inn a turning
stand.
Spinn the wheeell slowly andd reaadd the runout usinngg a dial
indiccaattoorr..
Actual runout is 1/2 the total indicator reading.

SERRVVIICCEELIIMMIITTSS: Radiaall:: 2.0 mmm (0.08 inn))
Axial: 22.00 mmm (00..0088inn))

Whheeeell balance VALVE STEM
CAUTION:
Whheeeellbballannccee ddiirectly affectss tthhe ssttabilityy, hhandling andd 15-3
oover all ssafety of thhe mmoottoorrccyyccllee..
Always cchheck bbalancce wwhheenn thhee tiirre hhas bbeen removed
frroomm thhe rriimm..

NOTTEE::
For optimumm balancee,, the tire balance mark (aa paint dot
onn the side wall)) must bee locatteedd next to the valve stem.
Remoouunntt the tire if necessssaarryy..

http://www.motorcycle.in.th

REARR WHEEL/SUUSSPPEENNSSIIOONN ROTATING DIRECnON tAR

NOTEE::
Note the rotating direction marks on the tire.

Remove the dust seals from the wheel.
Mount the wheel, tire, driven flange and brake disc as-
sembly in an inspection stand.
Spin the wheel, allow it to stop, and mark the lowest (fheavii--
est)) point of the wheel with a chalk.

Do this two or three times to verify the heaviest area..

If the wheel is balanced, it will not stop consistently inn the
same position.

To balance the wheel, install wheel weights on the high- I INSPECCTTIIOONN STAND
est side of the rim, the side opposite the chalk marks.
Adjust enough weight so the wheel will no longer stop inn
the same position when it is spun.

Do not add more than 60 grams to the wheel.

Whheeel bearinngg
Turn the inner racee of each bearingg with your finger.
Bearingss should turn smoothly and quietly. Also cheecckkthat
the bearingg outer racee fits tightly inn the hub.

Remove and discardd the bearinnggss if the raceess do not turn
smoothly and quietly, or if they fit loosely inn the hub and
flange.

NOTE:
Replacceethe wheel and flange bearings inn pairs.

1 WWHHEEEELL BBEEAARRIINNGG

Drivveenn sprocckket I
Check the condition of the final driven sprocket teeth.
Repllaaccee the sprocket if worn or damaged.

NOTTEE: o0 XOK NO GOOODD
X
* Ifthe final driven sprocket requires replacement, inspect
the drive chain and drive sprocket. ~~

* Nevveerr iinnssttaallll a new drive chaaiinn onn a wornn sprockeett or a
worn chain on new sprockets. Both chain and sprocket
must be inn good condition or the replacemmeenntt chain or
sprocket will wear rapidlyy..

15-44 http://www.motorcycle.in.th

REAARR WHEEL/SUSPENSION

DISASSSEEMMBBLLYY

Remoovvee the brakkee disc bolts andd brake disc.
Remoovvee the side collar andd dust seal..

Removvee the side collar andd dust seal. OUST SiEAL SrDE COLLAR
Remmoovvee the driven flange fromm the left wheel hubb..

NOTE::
If you will be disassembbllee the driven flange, remove the
driven sprocket nuts before removing the driven flange
from the wheel hub.

Remove the damper rubbers and Oa--rriinngg.

[l PER RUBB Eft$

O- RIN G

http://www.motorcycle.in.th 15-5

REAR WHEEL/SUSPENSION

Driven flaange bearing removal
Remove the driven flange bearing and colllaarr..

Wheel bearing removal

Install the bearing remover head into the bearinngg..
Fromm the opposite side install the bearinngg remover shaft
and drive the bearing out of the wheel hub.

TOOLS: 07746 -- 0050330000
Bearinngg remover head,, 12 mm
Bearinngg remover shaft 0774466-00005500110000

Remmoovvee the distance collar and drive out the other beaarr--
ing.

DIISTANCE COLLAR

1155--66 http://www.motorcycle.in.th

REARR WHEELL//SSUUSSPPEENNSSIIOONN

AASSEMBLY DISC

BOLT

COLLAR ORIVEN
FLANGE

DUST SEAL

OUST SEAL

DISTANCEE COLLAR

tilt O-RING NUT

.<iI DAMPER
RUBBER

Wheel bearingg installation

CAUTION:
Never install an old bearing has been removed, the bear-
inga must be repdlaacedd with a n ew one.

Drive a new right bearing squarely'with its marking side
facing out.

TOOLS:: 07749 -- 000110Q0Q0Q0Q
Driver
Attaacchhmmeenntt,, 37 x 400 rmnrmn 0774466-00001100220000
Pilot,, 122m m
07746 -- 0040200

Install the distance colllaarr,, then drive in the left side bear-
ing with its marking side facing out.

DISTANCE COLLAR

http://www.motorcycle.in.th 15-7

REAR WHEEL/SUSPENSION

Driven flange installation

OAIVER

Pack all bearing cavities with grease install the driven
fflange collar into a new driven flange bearing.

Drive a new driven flange bearing into tthe driven flange
using tthe special tools.

TOOLS: 0774499--0001100000000
Driver 0774466--00001100220000
Atttaacchhmmeenntt,, 37 x 40 mm
Pilott,, 12 mm -07746 - 0040200

Wheel assembly

Install the rear brake disc with the stamped mark "MIN.
TH, 3.5 mm" facing outside and install the brake disc bolts.

Tlighten the brake disc bolts to the specified torque.

TORRQQUUEE: 42 N'm (4.3 kgf·mm,, 311 IMbH-ftt))

Install a new dust seal and apply grease to the dust seal
lip. Install the right side colllaarr.

,1M"',,;

Do not get grrease on the brrake disscc or stopping powerr
will be redduucceedd..

Apply grease to the new O-ring.
Instaalllthe wheel damper rubbers sand O-ringg into the wheel
hub.

Insttaalll the driven flange assembly into the left wheel hub..

If the driven sprocket was removed, instaallll the driveenn
sprocket andd tightenn the nuts to the speciffiieedd torquee..

TOORRQQUUEE: 644 NN'mm (66..55 kkggff·m,, 47 IbHf4tt)

Apply greeaassee too the neww dust seeaall lips, thenn insttaallll iitt into
the driveenn flange.

Inssttaallll the siddee collar.

155--88 http://www.motorcycle.in.th

REAR WWHEEL/SUSPENSION

INSTALLATION

Install the drive chain adjusters into the swingarm..
Place the rear wheel into the frraammee..
Insert the rear axle through the right drive chain adjuster,
right side collar, rear wheeell,, left side collar and left chain
adjusstteerr.
Install the drive chain onto the driven sprockeett..
Install the rear axle nut.
Adjust the drive chain slack (page 3-1551)..

SHOCK ABSORBER

REMMOOVVAALL

Remove the rear cowl assembly (paggee22--221)..
Support the motorcycle securely using a hoist or equiva-
lent.
Removee the shock absorberr lower mounting bolt and nut.

Remove the shock absorber upper mounting bolt.
Removee the shock absorber.

INNSSPPEECCTTIIOONN BU S HII\ I GS

Visually inspectt thee shock absorber foor damage. 15-9
Cheecckk the following:
-DaDmampeprer unit for deformation or oiill leeaakkss

--UUppppeer anndd lower buusshhiinnggss for wear or dammaaggee
CCAAUUTTIIOONN::
• Doo nnot ddiisasnseemmbbllee tthhee sshhoock abbssoorrbbeerr..
• Reppllaaccee tthhee sshhock abssoorrbber if any ccoommppoonneennttiiss ddaamm--

agaeedd..

http://www.motorcycle.in.th

REAR WWHEEL/SUSPENSION
INSTALLATION

Install the shock absoorrbbeerr to the fframe.
Install and tighten tthe shock absorber upper mounting bolt
to the specified torque.
TORQQUUEE: 39 N·mm (4.0 kgf·.m, 29 IbfH.ftt)

Install the shock absorbeerr lower mounting bolt and nut
and tighten the nut to the specified torque.
TORQUE: 44 NN'mm 1(44.5 kggff·mm, 33 IbfH4tt))
Check the operation of the shock absorber (page 3--22001)..
Instaalll the rear cowl (pagee 2-221).

SSWWIINGGAARRMM

REMMOVVAALL

Remoovvee the rear wheel (paggee 155--3311..
Reemmoovvee the swingarm pivott caps.

RReemmoovveethhee ssccrreeww aanndd bbrraakkee hhoossee gguuiiddee..

1155--1100 http://www.motorcycle.in.th

REAR WHEEL/SUSPENSION

RReemmoovvee the reaarr braakkee caliper/bracket assemmbbly from the
swwiinnggaarrmm..

RReemmoovvee the boolts, anndd drivee chhaaiinn covveerr..
RReemmoovveethe shhoocckkabssoorrbbeerrlower mmoouunnttingg boolt anndd nut.

RReemmoovvee the swwinnggaarrmm pivot nnuut.
RReemmoovvee the swwingaarmm pivoott bolt fromm the left side and
remmoovvee the swwiinnggaarrmm..

DDIISSAASSSSEEMMBBLLYY

RReemmoovvee the drive chhaaiinn addjuusstteerrss..

http://www.motorcycle.in.th 155--1111

REAR WHEEEELL//SSUUSSPPEENNSSIIOONN SCREWICO' LI4.R

Checkk thhe chhaiinn slider for wear or damaggee.
Remoovvee the scrreeww,, colllar and chhaiinn slliiddeerr..

Checkk the rubbbberr buusshhiinnggssfor wear, damaggee or fatiigguuee..

ASSEMBLYY IW5HING
SWWINNGG ARM
CHAIN SLIDER

I

SCREW CHAAIINN ADJJUUSSTTEERR
http://www.motorcycle.in.th
15-1122

IInnssttaallltthhee cchhaaiinn sslider. RREEAARR WWHHEEEELL//SSUUSSPPEENNSSIIOONN
IInnssttaalll thhee ccoollllaarr aanndd tighhtteenn thhee ssccreww too thee ssppeecciiffiedd
torquuee.. seR W/cOLlll R

TTOORRQQUUEE: 55..99 NN·.mm (00..66kkggff·m., 4.3 IIbbff·.tftt))

PPllaaccee the drive chhaaiinn adjusters intoo thee swingarm.

ADJUSTEAS

INSTTAALLLLAATTIIOONN

Inssttaalll the swingarm onto the frame.
Inssttaalll the swingarmm pivot bolt to the frame from the left
side.
Temppooraarily tighten the swingarmm pivot nut.

Insttaallll the chainn cover to the swingarm by aligning the
chain cover boss with the groove on the swingarm.

http://www.motorcycle.in.th 15-13

REEAARR WHEEL/SUSPENSION

Insttaallll andd tighten the bolts securely.
lTigighhtten the shock absorber lower mounting bolt and nut
to the specifiedd torque.
TORRQQUUEE: 44 N·.m (4.5 kggff·.mm, 33 Ibbff·tftl)

Ilnstall the brakee hose guide and tighten the screw securellyy..

Instaallll the rear brake caliper/bracket assembly onn the
swingarm aligning the sloat onn the bracket with bboossss on
the swingarm.

Inssttaalll the rear wheel (paaggee 15-91),, thenn place the motor-
cycle onn levell ground.
lXigghhtteenn the swingarm pivot nnuuttto the speciffiieedd torque.

TORRQQUUEE: 88 N·.mm (99..00kkggff·m, 65 Ibbff·tftl)

Instaallll the pivot caps.

15-144 http://www.motorcycle.in.th

BRRAAKKEE SSYYSSTTEEMM

34 N·m (3.5 kgf·m, 25 Ibf·ft)

3344 N.·mm ((33..55kkggff·.mm,,255 IIbbf..fftt))

3344 N.·mm ((33.5.5kggff·mm,,255 IIbff.·fftt))
30 N.·mm (33..11 kkggff.m.m, ,22IIbbff·.fftt))

34 N·m (3.5 kgf.m, 25 Ibf·ft)

@/

~~

,.....

16-0 http://www.motorcycle.in.th

16. BRAKE SYSTEM

SERVICCEE INFORMATION 166--11 REAR MASTER CYLIINNDDEERR 16-12
TROUBLESHOOTING 16-16
BRAKKEE FLUIDD REPLACEMENTI/ 16-2 FRONT BRAAKKEE CALLIIPPEER 16-19
AIR BLLEEEEDDIINNGG 16-22
BRAKKEE PAD/DISC REAR BRAKKEE CALLIIPPEER
FRONT MASTER CYLINNDDEERR 16-3 BRAKKEE PEDALL
16-5

16-8

SEERRVVIICE INFOORRMMAATTIIOONN

GENERALL

Keeepp greasee off of brakee paddss and disc.

,iiiMM;

A coonnttaammiinnaatteeddbbrrake ddisc or pad reduuccess stopping poowweerr.. Discard ccoonnttaammiinnaatteeddppaaddssand cclleeann a ccoonnttaminatedd disc
wiitthh a high quualityy bbrrakke ddeggrreeassiinngg agenntt..

Never allow contammiinnaatteess (dirt,. water, etc.) to get into ann openn reservoir.
* Once the hydraulic system hass beenn opened, or if the brakee feels spongy, the system must bee bleed..
• Always use freshh DOT 3 or 4 brakee fluid fromm a sealed container when servicingg the system. DDo not mix different

types of fluidd they may not bee compatible.

CAUTTIIOONN::

Spilled brrakkee fluid will sseverely ddammaaggee instrruumment lennsseess and painted ssuurrffaacceess.. It is also harmful to ssome rubber
partss.
BBe ccarefull wwhhenever you remoovve thhe reservoir ccap; mmake ssuurre thhee front reservoir is horizontal fiirrsstt..

-• Always check brakkee operationn before ridingg the motorcyccllee..

SPECIFFIICCAATTIIOONNSS

ITEEMM I STAANNDDAARRDD Unit:: mm (inn))

Frontt Specciiffiieedd brake fluidd DOT 3 or DOT 4 1 ISERRVVIICCEELIMIT
Rearr Braakkee padd wear indicator
Braakkee disc thickness --- ---
Brakkee disc runout 3.8 -- 4.2 (0.1155 -- 0.17)
Master cylinder 1I..D0. To groove
Master piston 0O.D0. --- 3.0 (0.12)
Calioper cyvlinder 1I.D.0. 12.700 --1122..77443 (0.500000 -- 0.501177)) 0..11 (0.004)
Caliper piston 0O.D0. 12.657 --1122..66884 (0.4983 -- 0.499944)) 12.755 (0.5022)
Speciiffiieedd brake fluid 25.400 -- 25.405 (1.0000 --11.0.0000022)) 12.640 (0.4976)
Braakkee pDaadd wear indicator 25.450 (1.0020)
Braakkee disc thicknessss 25.318 -- 25.368 (0.9968 -- 0.998877)) 25.300 (0.9960)
Braakkee disc runout
Master cyvlinder 1I..D0. DOT 3 or DOT 4 ---
Master pistoonn 0O..0D.
Caliper cylinder 1I..D0. --- To gwrooove
CaliDpeer pDiissttoonn 0O.D0. 3.0 (0.12)
3.8 -- 4.2 (0.15 -- 0.17) 0..11 (0.00044))
12.755 (0.5002222))
--- 12.645 (0.4997788))
32.090 (1.2663344))
12.700 --1122..77443 (0.500000 -- 0.5017) 31.94 (1.257)
12.657 --1122..66884 (0.498833 -- 0.4994)
32.030 -- 32.080 (1.261100 --11.2.2663300))
31.948 -- 31.998 (1.257788 -- 1.2598)

http://www.motorcycle.in.th 166--11

BBRRAAKKEE SSYYSSTTEEMM 3344 NN.·mm ((33..55k1g<fg.mf·m, ,2255IIbbff.·fft)t) AALLOOCCbboolltt
11..55NN.m·m ((00..1155kkggfm·m,, 11..11 IIbbff.·ftf)t)
TTOORRQQUUEE VVAALLUUEESS 11..22 NN.·mm((00..1122 kkggfm·m,, 00.9.9IIbbff.·fftt))
55.9.9 NN.·mm((00.6.6kkggffm·m,,44.3.3IIbbff.·fftt))
BBrraakkee hhoossee bboolltt 3300 NN.·mm(\33.1 kkggfm·m,,22221Ibbf.·Rft))
FFrroonntt mmaasstteerrccyylliinnddeerrccoovveerrssccrreeww
FFrroonntt bbrraakke lliigghhttsswwiittcchh ssccrreeww 1177 NN·mm(\11..77 kkggfm·m,, 1122Ibf.·fftt))
BBrraakke lleevveerrppiivvoott nnuutt 11.5.5NN.·mm((00..1155kkggffm·m,, 11..11 IIbbff.·fftt))
FFrroonnttbbrraakkeeccaallipipeerr mmoouunnttiinngg bboolltt 1122 NN·mm (\11..22 kkggf·mm,, 991Ibf.·Rft)
BBrraakkee ccaallipipeerrppaadd ppiinn 1177 NN.·mm (\11..77 kkggff.·mm,, 1122 IIbbff.·fftt))
RReeaarr bbrraakke rreesseerrvvooiirrccoovveerrssccrreeww 55.4.4 NN·mm ((00..66 kkggf.mm,, 44IIbbf·Wft)
RReeaarr mmaasstteerrccyylliinnddeerr mmoouunnttiinngg bboollttss 2277 NN·mm (\22..88 kkgf·mm,, 2200 1Ibf.·Rft)
RReeaarr mmaasstteerrccyylliinnddeerr ppuush rrood nnuutt
BBlleeeedd vvaallvvee 007914 -- SSAA500011
MMaain sstteep hhoollddeerr mmoounting bboolltt

TTOOOL

SSnnap rring ppliers

TROUBLESHOOTlING B8rake leverl/pedal hard
• Clogged/reessttrriicctteedd brake system
Brake lever/ppeeddaall soft or spongy • Sticckkiinngg/whornn caliper piston
Air inn hydraulic system
- Caliper not sliding properly
- Leakinngg hydraulic system Clogged/hrestrictteedd fluid passage
Contaminated brakee pads/disc
Worn caliper piston seall -* Worn caliper piston seal
Sticckkiinngg/whornn master cylinder piston
- Worn master cylinder piston cups • Bent brake lever/pedal
Worn brakee pads/disc
8Brraakke drags
-- Contaminated caliper Contammiinnaatteedd brake paddsd/disc
Caliper not slidingg properly Misaalliiggnneedd wheel
Low braakkee fluidd leveell Clogged/restricteedd braakkee hosee joint
Warped/deformed braakkee disc
-* Clogggeedd fluidd ppaassssaaggee Caliper not slidingg properly
Warped/deformed brraakkee disc Clogged/restrictedd braakkee hydraulic systeemm
Sttiicckkiningg/whoorrnncaliper pissttoonn Sttiicckkiningg/wborrnn caliper piissttoonn
Sttiicckkiningg/whoorrnn mmaasstteerr cylinder pissttoonn Cllooggggeedd mmaster cylinder port

- Contaminated mmaasstteerr cylinder
- Beenntt brraakkee lever/pedal

1166--22 http://www.motorcycle.in.th

BRAAKKEE FLLUUIIDDREPLACEMENT/AIR FRONT: BBRRAAKKEE SSYYSSTTEEMM
BLEEEEDDIINNGG SET PLATE
f--.SCREWS
il§M¥iifiN
COVER
AA ccoonnttaammiinnaatteeddbbrraakkeeddiissccoorpadrreduceessssttooppppiinnggppoowweerr..
DDiissccaard cwonnttaammiinnaatedpadssaannd cclleeaannaaccoonnttaamrniinnaatteeddddiisscc
wwiitthh aahhiigghh qquuaalliittyybbrraakkee ddeeggrreeaassininggaaggeenntt..

CCAAUUTTIIOONN::

• Doonnoott aalllloowwffoorreeiiggnnmmaatteerriiaall tooeennteer tthheessyysstteemmwwhheenn
fillinngg thhee reesseerrvvooirir..

• AAvvooiidd ssppiilllliinnggfflluuiidd oonnppaaiinntteedd,, ppllaassttiicc,, oorr rruubbbbeerrppaarrttss..
PPllaaccee aa rag oover theessee parts wwhheenneevveerr thhee ssyysstemm Iis
sseerrvviicceedd..

~

NOOTTEE:: REAR:

* The peddaall brakee linee air bleedingg procedduurree iss peerr--
formeedd iinn the same maannnneerr ass iinn the leveerr brakee linnee

- air bleeeeddiinngg procedure.
OOnnccee tthhee hhyyddrraauulliicc ssyysstteemm hhaass bbeeeenn ooppeenneedd,, oorr iiff tthhee
brraakkee feels spongy, thee sysstteemm mustt bee bleedd..
Wheenn usiinngg a commercially avaiillaabbllee braakkee bleeder,
follow the manufacturer''ss operating instructions.

BRAKE FLUIIDD DRAININNGG REAR:
UPPER LEVEL
Make sure that the master cylinder is parallel to the ground,
before removing the reservoir cover.

Remove the screws, reservoir covveerr,, set piate and dia-
phragm.

Connect a bleedd hose to the bleed valvee..

Loosen the bleed valve and pump the brake lever (pedal)..
Stop operating the brake when no more fluid flows out of
the bleed valve..

BRAKE FLUID FILLING/BLEEDING

CAUTION:
Do not mix difffeerreenntt types offfluuiiddssiinncce theeyy are not com-
patible.

FFill the reservoir with DOT 3 or DOT 44 brake fluid to the
upper level.

http://www.motorcycle.in.th 16-3

BRAAKKEE SYSSTTEEMM

Conneecctt a commeercially avvaaiillaabbllee braakkee bleeder too thee
bleeeedd valve.
Pummpp the brakkee bleedeerr andd loosseenn the bleeeedd valve. Add
brakkee fluid when the fluidd levveell inn the reservooiirr iss loww..

NOOTTEE:
* Check the fluidd levveell oftenn while bleedingg the brakee to

preventt air fromm beiinngg pumppeedd intoo the system.
•* When usinngg a braakkee bleedinngg tool, follow the mannuu--

facturer’'s operating instructionnss..

Repeeaatt the above procedurreess untill air bubbles do not ap-
pear inn the bleeedd tube.

NOTE:
If air is entering the bleeder from around the bleeedd valve
threads, seall the threads with teflon tape.

Close the bleeedd valve and operate the brake lever (pedal).
If it still feels spongy, bleed the systemm again.

If a brake bleeder is not available, use the following pro-
cedure:
Pump up the system pressure with the brake lever (pedaall))
until lever (pedall)) resistance is felt.

11.. Pump the brake lever or pedal several times, then
squeeze the brake lever or push the brake pedal all the
way and loosen the bleed valve 1/2 turn. Wait several
seconds and close the bleed valve.

NOTE:
Do not releaasseethe brake lever or pedal until thea bleed valve
has been closed.

2.. Release the brake lever or pedal slowly until the bleed mREAR:
valve has been closed. 1 UPPERLEVEL I

3. Repeat steps 1-- 22 until there are no air bubbles in tthe

bleed hose.

AAftteerr bleeding air complleetteellyy,, ttiigghten the bleed valve tto
the ssppeecciffiieedd ttoorrqquuee..

TTOORQUE: 5..44 NN·mm 1(0.6 kkgf'mm,, 4 IbfH4t)

FFill tthe reservoir wwith D00OTT3 orr DOT 44 brake ffluid to the

upper level.

16-4 http://www.motorcycle.in.th

Inssttaalll the diaphragm set plaattee andd reservvooiirr coveerr.. ____ SSCCRREEWWSS BRAKEE SYSTEMM
Tliigghhtenn the reservoir cover screws to the specified torque. ~
SCREWS
TOORRQQUUEE: 1.5 NN·mm (0.155 kggf·fmm, 11..11 Ibff.fftt)) r COVER

DIAPHHRRAAGGMM DDIIAAPPHHRRAAGGMM SET PLAATTEE

BRAKEE PAD/DISC

FRONNTT BRAAKKEE PADD REPLLAACCEEMMEENNTT

i!ii.1f.i4iiiilN

A ccoonnttaammiinnaattedbbrrakkeeddiissccorpadrreducessstooppppiinnggpoowweerr..
Disccarddccoonnttaammiinnaatteeddppaaddssand cclleeaannaa ccoonnttaminatedd disc
wiitthh aa high quality brraakkee ddeggrreeassiinnggaggeenntt..

NOTE:
•* Always repllaaccee the brakee padss inn pairrss to assure even

disc pressuurree..
Check the brakee fluid leveell innthe brakee master cylinder
reservooiirr as this operation cauusseess the leveell to rise.

Puusshh the caliper pistons alll the way inn to allow installation
of new braakkee pads.

Remoovvee the paadd pinn andd brakee paddss..

http://www.motorcycle.in.th 16-5

BRAKEE SYSSTTEEMM

Insttaalll the new brakee padss to the brakee caliper.

r

Instaallll the new aO--rriing into the padd pin groove.
Apply grease to the padd pinn sliding surface.
Pusshh the brakee padss against the padd spring,, then install
the padd pin.
Tightenn the padd pinn to the speciffiieedd torque.
TORRQQUUEE: 177 N.'m (1..77 kgf·.m, 122 Ibff.4ftt))

REAR BRAKEE PADD REPLACEMMEENNTT

.Mn@....

A coonnttaammiinnaatteeddbrrakkeedisc orpad reduces stoppingpoowweerr..
Discard coonnttaammiinnaatteddpaddssand cllean a coonnttaminated disc
withh a8 high quality brake degrreasinngg agenntt..

-NOTE::
Check the brake fluid level inn the reservoir as this
operation causes the leveell to rise.
Always replace the brake pads inn pairs to assure evenn
disc pressure.

Pusshh the caliper pistonss all the way inn to allow installation
of new brakee pads.
Remove the rubber plug.

166--66 http://www.motorcycle.in.th

BRAKKEE SYSTEMM

Remove the padd pin and brakee pads.

Install the new O-ringg into the padd pinn groove.
Apply grease to the padd pin sliding surface.
Puusshh the brakkee pads against the padd spring,, then install
the paadd pinn..
TIighteenn the padd pinn to the specified torque.
TOORRQQUUEE: 17 NN·mm (1..77 kggff·m, 12IIbbff·4ftt)

Instaallll the rubber plug.

BBRRAAKKEE DIISSCC INSPECCTTIONN 166--77

Visually inspect the brraakkee disc for damage or craacckkss..
MMeeaassuurree the braakkee disc thickness withh a mmicrometer.
SEERRVVIICCEELLIIMMIITTSS::

FFRROONNTT:: 3.0 mmmm (00..1122 iinn))

REAR:: 3.0 mmmm (00..1122iinn))

RReeppllaacceethe brraakkeedisc iifftthhe smmaalllleesstt mmeeaassuurreemmeennttiss leessss
thaann thee servicee limit.

http://www.motorcycle.in.th

BBRAKE SSYYSSTEM

MMeeaassuurree tthhee bbrrake ddiisscc wwaarrppaaggee wwiitth aa ddiial iinnddiiccaattoorr..

SSEERRVICE LLIMITT::00..11 mmm ((0.00004siinn)

CChheck tthhee wwhheeeell bbeeaarriinnggssffoorreexxcessive ppllaayy,, iifftthheewwaarrppaaggee
eexceeds tthhe sseerrvvicce limmit.
Replace tthe brake diisscc iff tthhe wwheel bbearings aare nnormal.

FRONT MASTER CYLINDER MASTER WASHERS BOLT

REMOVAL f l r l iCYLINDER ___ HOSE

CAUTION:
Avvooiidd spilling fluiidd on painted, plastic, orr rubber parrttss.
Place a rag overr thesell parrttss whenevvellr the systemm iiss ser-
viccedd.

Drain the brake fluid from the front brake hydraulic sys- CONNECI TI O- RSN
tem (page 16-31)..

Remove the front brake light switch connectors..
Removeethe bolt, sealing washers and disconnect the brake
hose.

Removee the master cylinder holder blots, holder and mas-
ter cylinder.

DISASSEMMBBLLYY SCI'IEW UT

Remmoovvee the pivott nut, bolt andd braakkee lever.
Remmoovvee the screw anndd front brraakkee lightt switch.

BRA E L1G1-! SWITCH BOLT ,mAKE LEVER

1166--88 http://www.motorcycle.in.th

Remmoovvee the boot.. 5NN'AIN'G BRAKE SYSTEEMM
Remmoovvee the snap ringg using the special tool.
SNAP RING PLIERS

TOOOOLL: -079144 - SAA5500000011
Snap ringg plierss

Remoovvee the washer, master piston and spring from the SP RI N G
master cylinder. J>FlrMAIRY CAP
Cleeaann the inside of the master cylinder and reservoir with
brakee fluid. SNAP lUNG

NOTE: SE.CONDARY CAl"
Cleaann the disassemmbblleedd parts with cleaann brake fluid and
make sure air cann ventilate the master cylinder port by W A S HEfl
compressed air.

INSPECTTIIOONN

Check the boot, primary and secondary cups for wear, de-
terioration or damage.
Check the master cylinder and piston for scoring or other
damage.
Reppllaaccee if necessary.

Measure the master cylinder I.D.
SERVIICCEE LIMMIITT:: 12.755 mmmm (0.5002222 in)

Measure the master pistonn O.D.

SERVVIICCEE LLIIMMIITT:: 12.640 mmm (0.49766 in)

NOTEE::
The master piston, pistoonn cups, spring and snap ring, must
bee replaaccee as a set.

http://www.motorcycle.in.th 16-9

BRAKKEE SYSTEM

ASSEMBLY

A COVER
\ IBO~OTSNAP RING SET PLATE
SjNAP RING A
\ HRAGM
A I \MASTERPISTON

': '@

/ \I

WASHER

CUPS

SPRING

BRAAKKEE LEVEERR B-R-A.K\..E- L. IGHT' SWITCCHH
SNAPRI G
CAAUUTTIIOONN::
Whheenn inssttaalling the cupss,, doo not alloow the lips to turn
inssidee ouutt..

Diipp the pisttoonn cups inn cleeaann brakee fluidd befoorree assembly.
Inssttaallll the spring onto the masster pistoonn..
Inssttaalll the spring/lmaster pisttoonn andd washer intoo the mas-
ter cylinder.

WASH ER

Inssttaalll the snap rinngg usingg the specciiaall tool. SNAPFlINO SNAP RI NG PUERS

TOOOOLL: 07914 -- SSAS5O00O0O1l
Snapp rriinngg pplliieerrss

CAAUUTTIIOONN::
Be ceerrttaainn the ssnnap ring is firmly sseeated in the groovvee..

Apply siliconnee greassee to the insidee of the booott..
Inssttaallll the boot to the master cylinder.

,...rifiit BOOT

16-1100 http://www.motorcycle.in.th

BRAKE SSYYSTEM

Install the front brake light switch onto the master ccylin- BI'1AK£ GHT S rCH
der with aligning the boss of the switch with hole off the
master cylinnddeerr..

Install and tighten the front brake light switch screw to ill
the specified torque.
~ eOLT BRAK[ lrVrR
TORQUEE:: 1.2 NN·mm (0.12 kkggff·.m. 0.99Ibbff·4ftl)

Apply silicone grease to the brake lever contacting area of
the master pistonn and pivot bolt sliding surface.
Instaallll the brake lever.
Instaallll and tighten the pivot bolt and nut to the specified
torque.

TOORRQQUUEE:
Pivot nnuutt:: 5.99 NN'mm (00..66 kkggff·.mm., 4.3 Ibbff·4ft)

Inssttaalll the master cylinder andd holder with the ·"UPP"· mark
facingg up.
Align the endd of the master cylinder with the punch mark
onn the handlebar., andd tighten the upper bolltt firstt,. then
tighten the lower bolt.

Coonnnneecctt thee brraakkee hoossee too the mmaassteer cylinder with the ....,
boolt anndd neeww sealing washers aass shown. MASTTEERR WASHERS .-.
Adjust thee brraakkee hoossee angle anndd tighten the bolt to the CYLINDDEERR ---......
specified torqquuee.. v

\\

TTOORRQQUUEE: 3344 NN·mm ((33..55kkggff·m., 2255 IIbbff·4ftt)) HOSE

CCoonnnneecctt thhee front bbrraakkee lliigghhtt sswwiittcchh ccoonnnneeccttoorrss..

FFiilllaanndd bblleeeedd tthhee froonntt bbrraakkee hhyyddrraauulliicc ssyysstteemm ((ppaaggee 6-33))..

http://www.motorcycle.in.th 166--1111

BRAKKEE SYSTEMM O-fil G

REAR MASTER CYLINDER

REMOVAL

CAUTION::
• Avoid ssppilling ffluid oonn ppainnttedd, ppllastic or rruubbbber ppaarrttss..

• Place a sshhop ttoowwel oovver tthheesseepparts wwhheennevver tthheessyyss-

ttermn iiss sseerrvviicceedd..

NOTTEE::
• Wheenn remoovviinngg the brakkee hossee bolt, cover the endd of

the hossee to prevent contaminaationn.
• Seccuurree the hosee to prevent fluiidd fromm leakingg out.

Drraaiinnthe brake fluidd froomm the rear brakkee hydraulic systeemm
(paaggee 166--33))..
Remmoovvee the brake hossee bolt, sealing washers andd brakee
hossee..
Remoovvee the rear master cylinder mounting boltss..
Remoovvee the mounting bolts andd right mainn step holder
with the rear brake light switch installed.
Removee the cotter pin, joint pinn andd rear master cylinder.
Remoovvee the bolt and reservoir.

DISASSEMBLY

Remmoovvee the screw, aO--rriinngg and joint pipe.

JOINT PIPE. SCREW
600T
Removee the boot.

16-12 http://www.motorcycle.in.th

Remoovvee the snap ringg usinngg the speciaall toooll. BRAKE SYSTEM

TOOOOLL: SNAF' INC
Snap rinngg plierss
-079144 - SSAASOWO0011

Remove the following: $Pfli G

-- pusshh roodd assembly
-- master pistoonn assembly
-- spring

Checkk the springg andd replaaccee if necceessssaarryy..

MAS ff R: PI$ TOI'4

INSSPPEECCTTIIOONN PflIMARY CUP

Checckkthe boot, primary cup andd secondary cup for fatigue MASTER SECONDAR
or damage. PISTO ClJP
Checkkthe master cylinder andd pistoonn for scoring, scratches
or other damage.
Reeppllaaccee if necceessssaarryy..

NOTEE::
Reeppllaaccee the pistonn assembly andd springg as a set if dam-
agedd..

MASTER CYLINDER

Measure the master cylinder boree 1I..D0..

SERVVIICCEELLIIMMIITT::1122..775555 mmm (0.5022 iinn))

Measure the master pistoonn 0O..D0.
SERVVIICCEE LLIIMMIITT: 12.645 mmm (0.497788 in)

http://www.motorcycle.in.th 16-13

BRAKKEE SYSTEMM
ASSEMBLY

I I CO~R JOINT PIPE
MASTER CYLINDER
~~~~
SET PLATE

\01 0 ,

~O DIAPHRAGM

NOOTTEE:: PUS ROD
• Makkee sure that eacchh part is free from dust or dirt beforree
/~
reassemmbbllyy..
SPRI NG
Coat the pistoonn cups with the recommmeennddeedd brakkee fluid.
Apply silicone grease to the pushh roodd contaaccttiinngg area of
the master cylindccrr..
Inssttaalll the spring onto the master piston.
Insttaallll the spring, master pistoonn andd pusshh roodd into the
master cylinder.

MAS TER PlSTON

Inssttaalll the snap ringg using the special tool.

S NAP RI G

TOOOOLL: -0791144 - SAA5500000011
Snnapp rriinngg pplliieerrss

Insttaalll the booott..

16-144 http://www.motorcycle.in.th

BRAKEE SYSTEM

Apply silicone greasee to the boot groove inn the pusshh rodd
andd instaallll the pistonn boot into the master cylinder.

If the pusshh rodd joint iss reinstalled, adjust the pusshh roodd
length so that the distance fromm the center of the master
cylinder lower mounting hole to the center of the joint pinn

- -hole is 84 - 86 mmm (3.3 - 3.4 inn))..

After adjustment tighten the lock nut.

TORQQUUEE:: 177 N·m (1..77 kkggff·m, 121IbbfH4tt)

Apply brakkee fluidd to the new O-rinngg..
Insttaalll the new O-riinngg andd joint pipe..
Tighteenn the screw secureellyy..

JOINT ~PE SCREW

INSTAALLLLAATTIIOONN 16-15

CAAUUTTION::
• After inssttalling thhe bbrraakkee hhoosse too thhe master ccyylliinnddeerr,,

mmake ssuurre it ddooeess not inntteerrffeerree witthh thhe movvement of
thhe shock abssoorrbbeerr..

Instaallll the reservvooiirr andd tighten the bolt.

Instaallll the joint pin.
Secuurree the joint pinn with a new cotter pin..

http://www.motorcycle.in.th

BRAKE SYSTEM

Temmoorraarriillyy install the rear masterr cylinder and mounting
bolts..
Install the right main step holder and tighten the mounting
bolts to the specified torque.

TORQQUUEE: 27 N'mm (2.88 kgff·mm, 20 Ibff.4ftt))

lTigighhtten the rear master cylinder mounting bolts.

Install the new sealing washers and brake hose and tighten
the bolt to the specified torque.

TORQQUUEE: 34 N.'m (\3.5 kggff·.mm,, 25 Ibbff.Wft)

Fill and bleed the rear brake hydraulicssyyssttem (page 166--331)..

FRONT BRAKE CALIPER

REMOVALL

CAUTIOONN::
Avoid spillliinngg fluid on painted, plastic or rruubbb~err partss.
Placcee a shop ttooww~e1l over tthhe~see parts whenever tthh~e ssyyss--
ttemm is ssenrvriicced..

Draaiinn the brakkee fluiidd fromm the front braakkee hydraulic sys-
temm (paggee 1166--331)..

Plaaccee a cleaann container under the caliper andd remmoovvee the
oiill bolt, sealliinngg washers andd eyelet joint froomm the caliperr..
Remmoovvee the braakkee caliper mounnttiinngg bolts andd caliper
assembly.
Remmoovvee the brakkee padss (paaggee 1166--551)..

DISASSEEMMBBLLYY

Remmoovvee thee following:
-- caliper bbraacckkeett
-- paadd sprinngg
-- bracket piinn bboooottss

RReemmoovvee thee calippeerr pistonnss..
If nneecceessssaarryy,, lightly apppllyy commpprreesssseeddair too thee fluuiidd innlleett
too get thee piissttoonn out.

PA[l SPRING B~ACKE T

1166--1166 http://www.motorcycle.in.th

BRAKE SYSTEM

Plaaccee a shop raagg under the caliper to cushhiioonn the piston
when it iss expeelllleedd,.
Usee the air inn short spurts.

'MUiiii;

Do not bring thhee air noozzle tooo clloossee to thhee inlet or the
pissttoonnssmay be foorrcceeddout witthh exccessssiivveefoorrccee that could
cauussee innjiuurryv..

Puusshh the dust andd pisttoonn sealss inn andd lift them out. DUST S€AL
Cleaann the seaall groove with cleaann braakkee fluid,.
CAAUUTTIIOONN::
Be carefull not to dammagge thhee piston slliiddiinngg suurrffaacce.

INSPECTIOONN

Checckk the caliper pistons for scorinngg or other damaaggee,.
Measure the caliper pisttoonn 0O,.0D.
SERRVVIICCEELLIIMMIITT::25.300 mm (00.99996600 inn))
Checckk the caliper cylinder boreess for scorinngg or other dam-
age.
Measure the caliper cylinder 1I.D0..
SERRVVIICCEE LLIIMMIITT::255..440000 mm (255.4055 inn))

http://www.motorcycle.in.th 16-1177

BRAKE SYSTEEMM ... DUSTSEAL
ASSEMBLY
PISTON SEAL
CALIPPEERR PISTOONN

CALIPER BRACKET

PAD PIN CALIPER CYLINDER PAD SPRING BRAKKEE PADDSS

Coat the new piston seals and dust seals with clean brakee
fluid and install them inn the seall grooves oftthhe caliper..

Lubricattee the caliper cylinders and pistons with clean brakkee
fluid and install the pistons into the caliper cylinders with
the openingg towards the padss..

PISTON SIEAL PISTON

If the caliper and bracket pinn boots are hard or deterio- ~ BOOTS
rated, replaccee them with new onneess..
Apply silicone grease to the bracket pinn boots and bracket
pinss and install them making sure that they are seated inn
the bracket ppiinn grooves properly.

Instaalll the padd springg on the caliper.

Assemble the caliper bracket and caliper body..

16-188 PAD Sp",ING
http://www.motorcycle.in.th

INSTALLATIONN BRAKE SYSTEM

Install the brake pads (pagee 16-6). 130 T
Install the brake caliperr and mounting bolts. P:AD SPRING
lTigighhtten the bolts to the specified torque.

TORQQUUEE: 30 N.·m (3..11 kggff-m, 22 Ibf·4ft)

Connect the brake hose eyelet joint with two new sealing
washers, then tighten the oil bolt to the specified torque.

TORQUE:: 34 N.'m (3.5 kgff·mm, 25 Ibf·4ft)

Fill and bleed the front brake hydrauric system (paggee1l6-
33))..

REAR BRAKE CALIPER

REMOVAL

Drain the brake fluid from the rear brake hydraulic system
(page 16-31),.
Remove the brake pads (page 16-5))..

Remove the bolt, sealing washers and brake hose eyelet
joint.

Remoovvee the rear wheel (page 15-33)).
Removee the brakee caliper.

DISASSEEMMBBLLYY

Removee the brake padd spring from the caliper bodyy..

Remmoovvee thee caliper bracket froomm the caliper boddyy.. BRAG -ET
Remmoovvee the brackeett piinn boots.
(lOOTS

CA LIf' R BODY

http://www.motorcycle.in.th 166--1199

BRAKKEE SYSSTTEEMM Pt<S. ON S A.l

If necessary, lightly apply compreesssseedd air to the fluid inlet OUSTS AI..
to get the piston out.
Placcee the shop ragg under the caliper to cushion the pistoonn
when it is expelled.
Use the air inn short spurts.

'¥Hliiii!'

Do not bring thhe air noozzle too cclloosse to thhe inlet or thhe
pistons may be forcced out wiitthh excessivve foorrccee that could
ccausse innjiuurryv..

Pusshh the dust seall and piston seaall inn and lift them out.
CAUTION:
BBe careful not to ddammaaggee thhe piston sliding suurrffaaccee..
Cleaann the seall grooves, caliper piston and caliper piston
sliding surface with cleann brake fluid.

INSPPEECCTTIIOONN

Check the caliper cylinder andd pistonnss for scoring,
scratches or damage.
Measure the caliper cylinder 1I.D.0.

SERVICE LLIMMIITT:: 3322..009900mm m (1.26344 in)

Measure the caliper pistonn 0O.D0..
SERVICE LIMMIITTSS:: 311.94 mm (11..225577 in)

16-20 http://www.motorcycle.in.th

BRAKEE SYSTEM

ASSEMBLY ...BOOTS

BRAACCKKEETT

PISTON SEAL
PISTON . .

PADD SSPPRRIINNGG Y/d
1

CALIPER CYLINDER
~AD~NPLUG
J
PAADDSS /
PAADn PINN
Coat the new pistonn seaall andd dust seall with cleaann brake
fluidd andd instaallll them inn the seall grooves of the caliper.

Apply brake fluidd to the caliper pistoonn andd instaallll it into
the caliper cylinder with the opening towards the pads.

If the caliper andd bracket pinn boots are hardd or deterio-- ElRACKrT
rated, replace them with new oness..
Apply silicone greasee to the bracket pinn boots andd bracket 166--2211
pinss andd instaallll them.
Make sure the boots are securely seated intoo the pinn
grooves.
Assemble the caliper bracket andd caliper bodyy..

http://www.motorcycle.in.th

BRAKE SYSTEM PAD SffilNG

Check the pad spring ffoorr damage aand replace it if neces-
ssaarryy..

Install the pad spring onto the caliper bodyy.

INSTALLATION

Install the rear brake calipedr/bbrraacckkeett assembly onto the
swingarm by aligning the bracket slot with the boss on
the swingarm.

Install the rear wheel (pagee 15-9')..
Install the brake pads (pagee 16-5)'.

Temporarillyy install the brake hose eyelet joint to the caliper
body with new sealingg washers and bolts. Pushh the brake
hose eyelet jOoiinnt to the stopperr on the caliper, then tighten
the bolt to the specifieedd torque.

TORRQQUUEE: 34 NN'mm (3.5 kggff·.m, 25 Ibf·4ttl

Filll and bleeedd the rear brake hydraulic system (pagee 16-3')..

BRAKEE PEDAL

REMOOVAAL

Remmoovveethe mountinngg bolts and right main step holderr..

Remmoovvee the brakee light switchh rettuurrnn spring. ........ __
Removvee the cotter pinn andd joint pin.
Removvee the cotter pin, washer, retuurrnn spring andd brakee
pedaall..

BRAKE PEDAL

166--2222 http://www.motorcycle.in.th

INSSTTAALLLLAATTIIOONN BRAKEE SYSTEMM

Apply grease to the peeddaall pivot sliding surfaaccee anndd inssttaallll 8RAKIE PEOAL
the braakkee peeddaall into the righhtt mmaaiinn step hoolddeerr..
SSeeccuurreethe braakkee peeddaallwith the washer anndd a new coottteerr
pinn..
Innssttaalll the joint pinn anndd new cotteerr piinn..
Innssttaalllthe braakkee light swwiittcchh spprrinngg to the reettuurrnn spprriinngg as
showwnn.

Innssttaalll the right mmaaiinn steepp hooldeerr anndd mmoouunnting boollttss..
Tligighhtenn the boolltss to the speecciifiedd torquuee..
TOORRQQUUEE: 27 N·.mm (2..88 kkggff·m., 20 IIbMf.-fftt))

http://www.motorcycle.in.th 16-233

CHARRGGIINNGG SYSTEM

SYSTEMM DIAGRAAMM

BATTERY

ALTERNATOR

I I

> == !

BATIERY
12V5AH

REGULATOAI o
RECTIFIER
Y:Y:Yeelloloww
G :Greeenn
R:Red
WW::WWhh~itee

17-0 http://www.motorcycle.in.th

17. CHARGINNGG SYSTEM

SYSTEMM DIAGGRRAAMM 17·-0 CHAARRGGIINNGG SYSTEMM INSPEECCTTIIOONN 17·-5
SERVICE INFORMATTIIOONN 17·-11 ALLTERNAATTOOR INSPEECCTTIIOONN 17·-7
TROUBLLEESSHHOOOOTTIINNGG 17·-3 REGULAATTOOR/RECTIFIER 17·-8
BAATlTERY 17·-4

SEERRVVIlCE INFFOORRMMAATI1O0NN

GENERALL

'¥I@"'"

• TThheebattery givess off expplloossiivveegases; keepp spaarkss, flameess and cigaarreetttteessawaayy. Proovviiddeeadeeqquuaattee vennttiillaattiioonnwhenn
chhaarrggiinngg..

• TThheebattery connttaaiinnss sulfuric acid (lelectrolyte). CCoonntact witthh skin or eyeess may caauusseeseveerree burns. WWeeaar protectivvee
clothingg and aa faccee shield.

-IfIf electrolyte gets on your skinn,, flusshh withh wwaatteerr..
- IfIf electrolyte gets in your eyeess,, flusshh withh water for at least 1155minutes and call a physician immmeeddiiaatteellyy..

-• Elecctroolyytee is poisoonnoouuss..
- If swallowed, drink largee quaannttiittiieess of water or milk and follow witthh milk of maggnneessia or veeggeettaabblleeoil and call a
phyyssiicciiaann.. KKEEEP OOUT OF REACH OF CCHHIILLDDRREENN..

* Always turn off the ignitiioonn switch before disconnectinngg any electrical components.

CAUTTIIOONN::

Soommee electrical commppoonneennttss may be dammaaggeedd if terminals or connnneeccttoorrss are conneecctedd or discoonnnneecctt whilee the
iganition switch is OON and aa current is pmresent.

* For extennddeedd storage, removvee the battery, give iita fuull charge andd store iittinna cool, dry space. For maximum service
life, charge the storeedd battery every two weeks.

* For battery remaining inn a stored motorcycle, disconnect the negative battery cablee from the battery terminal.
The battery cann bee damageedd if overcharggeedd or undercharged, or if left to discharge for long periods. These same
conditions contribute to shortening the life-ssppaann of the batteryy.. Eveenn under normal use, the performance of the
batteryy deterioraatteess after 2--33years.

- Battery voltage may recover after battery chargingg,, but under a heavy load, batteryy voltage will drop quickly and

eventuallyy the battery will bee completely discharged. For this reason, the charginngg system iss often suspectteedd to be
the problem. Battery overcharge often results inn problems innthe batteryy itself, which may appear to be an overcharge

msymptom. If one of the battery cells is shorted and the battery voltage does not increaassee,, the regulator/reccttiiffiieerr

. supplies excess voltage to the battery. Under these conditionss,, the electrolyte leveell drops quickly.
Beforree troubleshooting the charginngg system, check for proper usee andd maintenance of the battery. Check if the
batteryy is frequently under a heavy load, such as havingg the headlight and taillight ONN for long periods of time

- without ridiinngg the motorccyyccllee..
The battery willl self-discharge when the motorcycle is not usee.. For this reason, charge the battery every two weeks

- to prevent sulfation from forming.
When checkkiinngg the charging system, always follow the stepss inn the troubleshooting flow chart (paggee 17-31)..
Alternator serviciinngg cann bee done with the engine inn the frame.

http://www.motorcycle.in.th 177--11