HOME 2.18 REAR BRAKE CALIPER REMOVAL 2. Install caliper to caliper bracket fastener and tighten to 58- 66 Nm (43-48 ft-lbs). NOTE If removing caliper, remove brake pads first. If only replacing brake pads, do not remove rear brake caliper. Should pad replacement be necessary, see 1.11 BRAKE PADS AND DISCS . Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a) 1. Drain master cylinder brake reservoir using a suction device. 3. Connect brake line to caliper using two new copper washers and banjo bolt. Tighten to 23-26 Nm (17-19 ft- lbs). 2. Remove saddlebag if necessary to gain access to rear brake 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) Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a) 3. Remove banjo bolt and both copper washers to detach rear brake line from caliper. Discard washers. 4. With motorcycle supported from underneath, remove fastener from caliper.
NOTE Caliper can be removed without rear wheel removal. Follow steps above and remove fastener shown and remove caliper. Fastener torques is 58-66 Nm (43-48 ft-lbs). 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- formed. Failure to comply can result in cosmetic damage. (00239b) sm02166 4. Remove radiator side cover to access master cylinder. See 2.17 REAR BRAKE MASTER CYLINDER AND RESERVOIR . Remove cover from rear brake master cyl- inder. Fill master cylinder with D.O.T. 4 BRAKE FLUID. Verify that fluid level is at the FILL LEVEL boss when the motorcycle is level.
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 5. Bleed brake system. See 1.12 BLEEDING BRAKES . 6. Install radiator side cover. Figure 2-42.Two-Piece Caliper Fastener Location 7. Test brake system. 5. Lift rear caliper away from axle and Swingarm. a. Turn ignition switch ON. Pump brake foot pedal to verify operation of brake lamp. INSTALLATION b. Test ride motorcycle. If brakes feel spongy, bleed the system again. See 1.12 BLEEDING BRAKES . 1. Place caliper on caliper bracket with notch inside swingarm weldment.
Verify that rubber bumper is contacting under- side of the caliper weldment for the full length of bumper. NOTE Avoid making hard stops for the first 160 km (100 miles). This allows the new pads to become conditioned to the brake discs. 2009 VRSC Service: Chassis 2-45