HOME 2.16 FRONT BRAKE CALIPER REMOVAL INSTALLATION NOTE 1. Figure 2-37 . Attach calipers to fork legs. If only replacing brake pads, see 1.11 BRAKE PADS AND DISCS . a. Place caliper over brake disc with bleeder valve facing upwards. b. Place ABS bracket on caliper (if ABS equipped and left side only). Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a) c. Loosely install upper mounting bolt (4) into top hole on fork leg. d. Install lower mounting bolt (5) into bottom hole on fork leg. Tighten bottom mounting bolt to 43-52 Nm (32- 38 ft-lbs). 1. Drain master cylinder reservoir using a suction device. 2. See Figure 2-37 .
Remove banjo bolt (3) and both copper washers (2) to detach front brake line (1) from caliper. Discard washers. e. Final tighten the top mounting bolt to 43-52 Nm (32- 38 ft-lbs). 3. Remove both upper (4) and lower (5) mounting bolts (if ABS equipped, move ABS bracket out of the way). Lift caliper upward to remove from brake disc. 4. Repeat for opposite side caliper. Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) formed. Failure to comply can result in cosmetic damage. (00239b) Figure 2-37. Front Brake Caliper Mounting (ABS model shown) 4. Remove cover from front brake master cylinder.
Fill master cylinder with D.O.T. 4 BRAKE FLUID.Verify that fluid level is at FILL LEVEL when the motorcycle is level. 5. Tighten cover screws to 0.8-1.2 Nm (7-11 in-lbs ). sm04530 3 2 2 4 1 5 1. Front brake line 2. Copper washer 3. Banjo bolt 4. Upper mounting bolt 5. Lower mounting bolt 2. Connect the brake line (1) to caliper using two new copper washers (2) and banjo bolt (3). Tighten to 23-26 Nm (17- 19 ft-lbs). 3. Repeat for opposite side caliper. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T.
4 brake fluid can cause digestive discomfort. If swallowed, obtain medical atten- tion. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- After servicing brakes and pump brakes to build brake s pressure can adversely affec could result in death or serio 6. Bleed brake system and 1.12 BLEEDING BRAKES. 2009 V before moving motorcycle, ystem pressure. Insufficient t brake performance, which us injury. (00279a) tighten bleeder valve. See RSC Service: Chassis 2-39