Specifications

Item	Standard	Service Limit
Brake Lever, Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position	5-way adjustable (to suit rider) Non-adjustable Non-adjustable About 40 mm (1.6 in.) below top of footpeg	– – – – – – – – – – – –
Brake Pads Lining Thickness: Front Rear	4.5 mm (0.18 in.) 5.0 mm (0.20 in.)	1 mm (0.04 in.) 1 mm (0.04 in.)
Brake Disc Thickness: Front: EX650A Models EX650B Models Rear Runout	4.3  4.7 mm (0.17  0.19 in.) 4.8  5.2 mm (0.19  0.20 in.) 4.8  5.2 mm (0.19  0.20 in.) 0.15 mm (0.006 in.) or less	4.0 mm (0.16 in.) 4.5 mm (0.18 in.) 4.5 mm (0.18 in.) 0.3 mm (0.01 in.)
Brake Fluid Grade	DOT4	– – –

Special Tools

Inside Circlip Pliers: 57001-143

Hand Tester: 57001-1394

Jack: 57001-1238

Jack Attachment: 57001-1608

Brake Lever Position Adjustment

The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand.

_• Push the lever forward and turn the adjuster [A] to align

the number with the arrow mark [B] on the lever holder.

○^{The distance from the grip to the lever is minimum at num-}

ber 5 and maximum at number 1.

Brake Pedal Position Inspection

_• Check that the brake pedal [A] is in the correct position. Footpeg [B]

Pedal Position

Standard: About 40 mm (1.6 in.) [C] below top of footpeg

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTE

○^{Usually it is not necessary to adjust the pedal position,}

but always adjust it when the push rod locknut has been

loosened.

_• Remove:

Frame Cover (see Frame Cover Removal in the Frame

chapter) Bolts [A]

Right Footpeg Stay [B]

_• Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position.

If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), the pedal position will be within the standard range.

_• Tighten:

Torque - Rear Master Cylinder Push Rod Locknut: 18 N·m

(1.8 kgf·m, 13 ft·lb)

_• Install the footpeg stay, and tighten the bolts.

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

_• Check the brake light switch operation (see Brake Light Switch Operation Inspection in the Periodic Maintenance

chapter).

Brake Lever, Brake Pedal

Brake Pedal Removal

_• Remove:

Frame Cover (see Frame Cover Removal in the Frame

chapter) Bolts [A]

Right Footpeg Stay [B]

_• Remove: Cotter Pin [A]

Joint Pin [B]

Rear Brake Light Switch Spring [C] Return Spring [D]

_• Remove the mounting bolt [E] and take out the brake

pedal.

Brake Pedal Installation

_• Apply grease to the pivot shaft [A] and install the washer [B].

_• Install:

Brake Pedal [C]

Washer [D]

Brake Pedal Bolt [E]

Torque - Brake Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

_• Hook the lower end of the rear brake light switch spring [A] on the pedal hook.

_• Hook the upper end of the return spring [B] on the pedal

hook.

_• Replace the cotter pin with a new one.

_• Insert the cotter pin [A] and bend the pin ends [B].

_• Install the right footpeg stay, and tighten the bolts.

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

○^{Depress the brake pedal [A] and then align the bolts holes} of the master cylinder [B].

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

_• Check the brake pedal position (see Brake Pedal Position Inspection).

Front Caliper Removal

_• Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

_• Unscrew the caliper mounting bolts [B], and detach the

caliper [C] from the disc.

_• Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).

NOTE

○^{If the caliper is to be disassembled after removal and if}

compressed air is not available, disassemble the caliper

before the brake hose is removed (see Front Caliper Disassembly).

Rear Caliper Removal

_• Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

_• Unscrew the caliper mounting bolts [B], and detach the

caliper [C] from the disc.

_• Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation).

NOTE

○^{If the caliper is to be disassembled after removal and if}

compressed air is not available, disassemble the caliper

before the brake hose is removed (see Rear Caliper Disassembly).

Caliper Installation

_• Install the caliper and brake hose lower end.

○^{Replace the washers on each side of hose fitting with new}

ones.

_• Tighten:

Torque - Caliper Mounting Bolts

Front: 34 N·m (3.5 kgf·m, 25 ft·lb)

Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)

Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

_• Check the fluid level in the brake reservoirs.

_• Bleed the brake line (see Brake Line Bleeding).

_• Check the brake for good braking power, no brake drag,

and no fluid leakage.

Calipers

Front Caliper Disassembly

_• Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter.

Front Caliper Assembly

_• Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter.

Rear Caliper Disassembly

_• Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter.

Rear Caliper Assembly

_• Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter.

Caliper Fluid Seal Damage

The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.

_• Replace the fluid seal if it exhibits any of the conditions

listed below.

○^{Brake fluid leakage around the pad.}

○^{Brakes overheat.}

○^{Considerable difference in inner and outer pad wear.}

○^{Seal and piston are stuck together.}

If the fluid seal is replaced, replace the dust seal [B] as

well. Also, replace all seals every other time the pads are changed.

Rear Caliper Dust Boot and Friction Boot Damage

_• Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged.

If they show any damage, replace it.

Caliper Piston and Cylinder Damage

_• Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly

scores or rusty.

Rear Caliper Holder Shaft Wear

The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.

_• Check to see that the caliper holder shafts are not badly

worn or stepped, and that the rubber friction boots are not

damaged.

If the rubber friction boot is damaged, replace the rubber friction boot. To replace the friction boot, remove the pads and the caliper bracket.

If the caliper holder shaft is damage, replace the caliper bracket.

Brake Pads

Front Brake Pad Removal

_• Remove the front caliper with the hose installed (see Front Caliper Removal).

_• Draw out the holder shaft pin [A], and take off the holder

shaft [B].

_• Remove the pad [C] on the piston side.

_• Push the holder [D] towards the piston, and remove the

pad of the other side [E] from the holder shaft [F].

Front Brake Pad Installation

_• Push the caliper pistons in by hand as far as they will go.

_• Install the anti-rattle spring in its correct position.

_• Install the pad on the piston side first, then install the other

pad on the holder.

_• Install the front caliper (see Caliper Installation).

Rear Brake Pad Removal

_• Remove the rear caliper with the hose installed (see Rear Caliper Removal).

_• Draw out the holder shaft pin [A], and take off the holder

shaft [B].

_• Remove the pad [C] on the piston side.

_• Push the holder [D] towards the piston, and remove the

pad of the other side [E] from the holder shaft [F].

Rear Brake Pad Installation

_• Push the caliper piston in by hand as far as it will go.

_• Install the anti-rattle spring in its correct position.

_• Install the pad on the piston side first, then install the other

pad on the holder.

_• Install the rear caliper (see Caliper Installation).

Brake Pad Wear Inspection

_• Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter.

Front Master Cylinder Removal

_• Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose Removal/In-

stallation).

_• Disconnect the front brake light switch connectors [A].

_• Unscrew the clamp bolts [B], and take off the master cylin-

der as an assembly with the reservoir, brake lever and

brake switch installed.

_• Remove:

Brake Lever Pivot Bolt [A] and Locknut

Brake Lever [B]

Front Brake Light Switch [C]

Front Master Cylinder Installation

_• Install the front master cylinder so that the punch mark [A] of the handlebar is aligned with the mating surface [B] of

the master cylinder clamp to level the reservoir.

_• The master cylinder clamp must be installed with the ar- row mark [A] upward.

_• Tighten the upper clamp bolt [B] first, and then the lower

clamp bolt [C]. There will be a gap at the lower part of the

clamp after tightening.

Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

_• Replace the washers on each side of the hose fitting with

new ones.

_• Tighten the brake hose banjo bolt.

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

_• Bleed the brake line (see Brake Line Bleeding).

_• Check the brake for good braking power, no brake drag,

and no fluid leakage.

Master Cylinder

Rear Master Cylinder Removal

_• Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation).

_• Unscrew the master cylinder mounting bolts [A].

_• Remove the cotter pin [B].

NOTE

○^{Pull off the joint pin while pressing down the brake}

pedal.

_• Pull off the reservoir hose lower end [C], and drain the brake fluid into a container.

_• Remove the master cylinder.

Rear Master Cylinder Installation

_• Replace the cotter pin [A] with a new one.

_• Replace the washers on each side of hose fitting with new

ones.

_• Tighten the following bolts.

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

_• Bleed the brake line (see Brake Line Bleeding).

_• Check the brake for good braking power, no brake drag,

and no fluid leakage.

Front Master Cylinder Disassembly

_• Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

_• Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Master Cylinder Assembly

_• Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Master Cylinder Inspection

_• Remove the master cylinders (see Front/Rear Master Cylinder Removal).

_• Disassemble the front and rear master cylinders.

_• Check that there are no scratches, rust or pitting on the

inner wall [A] of each master cylinder and on the outside

of each piston [B].

If a master cylinder or piston shows any damage, replace them.

_• Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged softened (rotted), or swollen,

the piston assembly should be replaced to renew the cups.

If fluid leakage is noted at the brake lever, the piston as- sembly should be replaced to renew the cups.

Front Master Cylinder [J]

_• Check the dust covers [E] for damage. If they are damaged, replace them.

_• Check the piston return springs [F] for any damage.

If the springs are damaged, replace them.

_• Check that relief port [G] and supply port [H] are not plugged.

If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

Rear Master Cylinder [K]