12-8 BRAKES

Brake Lever, Brake Pedal

Brake Lever Position Adjustment

The brake lever adjuster has 6 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 number 6 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 75 mm (2.95 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 push rod locknut has been loosened.

•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 (2.8 ±0.04 in.), the pedal position will be within the standard range.

•Tighten:

Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m (1.7 kgf·m, 13 ft·lb)

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

Brake Pedal Removal

•Remove:

Rear Master Cylinder Mounting Bolts [A] Foot Guard [B]

Front Footpeg Bracket Bolts [C]

BRAKES 12-9

Brake Lever, Brake Pedal

•Remove: Cotter Pin [A] Joint Pin [B]

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

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

Brake Pedal Installation

•Apply grease to the footpeg pivot shaft [A].

•Install: Bushing [B]

Brake Pedal [C]

•Apply a non-permanent locking agent to the threads of the brake pedal mounting bolt [D], and tighten it.

Torque - Brake Pedal Mounting Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

•Hook the return spring [A] on the brake pedal and front footpeg bracket [B] as shown in the figure.

•Hook the rear brake light switch spring [C] on the switch and return spring as shown in the figure.

•Replace the cotter pin with a new one.

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

12-10 BRAKES

Brake Lever, Brake Pedal

•Install the front footpeg bracket.

•Tighten:

Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Install the rear master cylinder [A] and foot guard.

NOTE

○Depress the brake pedal [B] and then align the holes of the master cylinder.

○After installation, check that the rear brake light switch spring is hooked on the return spring.

•Tighten:

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).