Brakes Table of Contents
Exploded View................................... |
12-3 |
Brake Hose Removal/Installation. |
12-28 |
Specifications .................................... |
12-12 |
Brake Hose Inspection................. |
12-28 |
Special Tools ..................................... |
12-13 |
Anti-Lock Brake System .................... |
12-29 |
Brake Lever, Brake Pedal.................. |
12-14 |
ABS Servicing Precautions.......... |
12-32 |
Brake Lever Position Adjustment. |
12-14 |
ABS Troubleshooting Outline....... |
12-34 |
Brake Pedal Position Inspection .. |
12-14 |
Inquiries to Rider.......................... |
12-37 |
Brake Pedal Position Adjustment. |
12-14 |
Self-diagnosis Outline .................. |
12-39 |
Brake Pedal Removal .................. |
12-15 |
Self-diagnosis Procedures........... |
12-39 |
Brake Pedal Installation ............... |
12-15 Service Code Clearing |
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Calipers 12-17
Front Caliper Removal 12-17
Rear Caliper Removal 12-17
Procedures 12-40
How to Read Service Codes 12-42
How to Erase Service Codes 12-42
Caliper Installation ....................... |
12-17 ABS Indicator Light (LED) |
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Front Caliper Disassembly........... |
12-18 |
Inspection.................................. |
12-44 |
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Front Caliper Assembly................ |
12-18 |
ABS Indicator Light (LED) is |
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Rear Caliper Disassembly ........... |
12-18 |
Unlit (When the Ignition Switch |
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Rear Caliper Assembly ................ |
12-18 |
turned to ON) ............................ |
12-44 |
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Caliper Fluid Seal Damage.......... |
12-18 |
Solenoid Valve Inspection |
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Rear Caliper Dust Boot and |
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(Service Code 13,14,17,18) ...... |
12-45 |
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Friction Boot Damage ............... |
12-18 |
ABS Solenoid Valve Relay |
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Caliper Piston and Cylinder |
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Inspection (Service Code 19).... |
12-45 |
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Damage..................................... |
12-19 |
Front, Rear Wheel Rotation |
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Brake Pads ........................................ |
12-20 |
Code 25) ................................... |
12-47 |
12 |
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Front Brake Pad Removal............ |
12-20 |
ABS Pump Motor Relay |
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Front Brake Pad Installation......... |
12-20 |
Inspection (Service Code 35).... |
12-47 |
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Rear Brake Pad Removal ............ |
12-20 |
Front Wheel Rotation Sensor |
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Rear Brake Pad Installation ......... |
12-20 |
Signal Abnormal (Service Code |
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Brake Pad Wear Inspection ......... |
12-20 |
42) ............................................. |
12-48 |
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Master Cylinder ................................. |
12-21 |
Front Wheel Rotation Sensor |
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Front Master Cylinder Removal ... |
12-21 |
Wiring Inspection (Service Code |
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Front Master Cylinder Installation |
12-21 |
43) ............................................. |
12-49 |
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Rear Master Cylinder Removal.... |
12-22 |
Rear Wheel Rotation Sensor |
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Rear Master Cylinder Installation. |
12-22 |
Signal Abnormal (Service Code |
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Front Master Cylinder |
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44) ............................................. |
12-50 |
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Disassembly.............................. |
12-22 |
Rear Wheel Rotation Sensor |
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Rear Master Cylinder |
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Wiring Inspection (Service Code |
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Disassembly.............................. |
12-22 |
45) ............................................. |
12-51 |
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Master Cylinder Assembly ........... |
12-22 |
Power Supply Voltage Abnormal |
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Master Cylinder Inspection .......... |
12-23 |
(Under-Voltage) (Service Code |
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Brake Disc ......................................... |
12-24 |
52) ............................................. |
12-51 |
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Brake Disc Removal .................... |
12-24 |
Power Supply Voltage Abnormal |
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Brake Disc Installation ................. |
12-24 |
(Over-Voltage) (Service Code |
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Brake Disc Wear .......................... |
12-24 |
53) ............................................. |
12-52 |
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Brake Disc Warp .......................... |
12-24 |
ECU Inspection (Service Code |
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Brake Fluid ........................................ |
12-25 |
55) ............................................. |
12-53 |
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Brake Fluid Level Inspection........ |
12-25 |
ABS Hydraulic Unit Removal ....... |
12-53 |
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Brake Fluid Change ..................... |
12-25 |
ABS Hydraulic Unit Installation .... |
12-54 |
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Brake Line Bleeding..................... |
12-25 |
ABS Hydraulic Unit Inspection ..... |
12-55 |
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Brake Hose........................................ |
12-28 |
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Rear Caliper Holder Shaft Wear .. 12-19 Difference Abnormal (Service
Front Wheel Rotation Sensor |
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Wheel Rotation Sensor Rotor |
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Removal .................................... |
12-55 |
Inspection.................................. |
12-57 |
Front Wheel Rotation Sensor |
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Brake Hose and Pipe |
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Installation ................................. |
12-56 |
Removal/Installation.................. |
12-57 |
Rear Wheel Rotation Sensor |
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Brake Hose and Pipe Inspection.. |
12-58 |
Removal .................................... |
12-56 |
ABS Solenoid Valve Relay Fuse |
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Rear Wheel Rotation Sensor |
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Removal.................................... |
12-58 |
Installation ................................. |
12-56 |
ABS Motor Relay Fuse Removal . |
12-58 |
Wheel Rotation Sensor |
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Fuse Installation........................... |
12-58 |
Inspection.................................. |
12-57 |
Fuse Inspection............................ |
12-59 |
Wheel Rotation Sensor Air Gap Inspection 12-57
Dummy Page
No. |
Fastener |
Torque |
Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Bleed Valve |
7.8 |
0.80 |
69 in·lb |
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2 |
Brake Hose Banjo Bolts |
25 |
2.5 |
18 |
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3 |
Brake Lever Pivot Bolt |
1.0 |
0.10 |
9 in·lb |
Si |
4 |
Brake Lever Pivot Bolt Locknut |
5.9 |
0.60 |
52 in·lb |
|
5 |
Front Brake Disc Mounting Bolts |
27 |
2.8 |
20 |
L |
6 |
Front Brake Light Switch Screw |
1.0 |
0.10 |
9 in·lb |
|
7 |
Front Brake Reservoir Cap Screws |
1.0 |
0.10 |
9 in·lb |
|
8 |
Front Caliper Mounting Bolts |
34 |
3.5 |
25 |
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9 |
Front Master Cylinder Clamp Bolts |
8.8 |
0.90 |
78 in·lb |
S |
B: Apply brake fluid.
L: Apply a non-permanent locking agent. R: Replacement Parts
S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).
No. |
Fastener |
Torque |
Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Bleed Valve |
7.8 |
0.80 |
69 in·lb |
|
2 |
Brake Hose Banjo Bolts |
25 |
2.5 |
18 |
|
3 |
Brake Pedal Bolt |
8.8 |
0.90 |
78 in·lb |
|
4 |
Rear Brake Disc Mounting Bolts |
27 |
2.8 |
20 |
L |
5 |
Rear Caliper Mounting Bolts |
25 |
2.5 |
18 |
|
6 |
Rear Master Cylinder Mounting Bolts |
25 |
2.5 |
18 |
|
7 |
Rear Master Cylinder Push Rod Locknut |
18 |
1.8 |
13 |
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B: Apply brake fluid. G: Apply grease.
L: Apply a non-permanent locking agent. R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).
EX650B Models
No. |
Fastener |
Torque |
Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Bleed Valve |
7.8 |
0.80 |
69 in·lb |
|
2 |
Brake Hose Banjo Bolts |
25 |
2.5 |
18 |
|
3 |
Brake Lever Pivot Bolt |
1.0 |
0.10 |
9 in·lb |
Si |
4 |
Brake Lever Pivot Bolt Locknut |
5.9 |
0.60 |
52 in·lb |
L |
5 |
Brake Pipe Joint Nuts |
18 |
1.8 |
13 |
|
6 |
Front Brake Disc Mounting Bolts |
27 |
2.8 |
20 |
|
7 |
Front Brake Light Switch Screw |
1.0 |
0.10 |
9 in·lb |
|
8 |
Front Brake Reservoir Cap Screws |
1.0 |
0.10 |
9 in·lb |
|
9 |
Front Caliper Mounting Bolts |
34 |
3.5 |
25 |
|
10 |
Front Master Cylinder Clamp Bolts |
8.8 |
0.90 |
78 in·lb |
S |
B: Apply brake fluid.
L: Apply a non-permanent locking agent. R: Replacement Parts
S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).
No. |
Fastener |
Torque |
Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Bleed Valve |
7.8 |
0.80 |
69 in·lb |
|
2 |
Brake Hose Banjo Bolts |
25 |
2.5 |
18 |
|
3 |
Brake Pedal Bolt |
8.8 |
0.90 |
78 in·lb |
|
4 |
Brake Pipe Joint Nuts |
18 |
1.8 |
13 |
|
5 |
Rear Brake Disc Mounting Bolts |
27 |
2.8 |
20 |
L |
6 |
Rear Caliper Mounting Bolts |
25 |
2.5 |
18 |
|
7 |
Rear Master Cylinder Mounting Bolts |
25 |
2.5 |
18 |
|
8 |
Rear Master Cylinder Push Rod Locknut |
18 |
1.8 |
13 |
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B: Apply brake fluid. G: Apply grease.
L: Apply a non-permanent locking agent. R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).