Content .. 10 11 12 13 ..

Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013) - page 12

11-10 FINAL DRIVE

Drive Chain

•

After staking, check the staked area of the link pin for
cracks.

•

Measure the outside diameter [A] of the link pin and link
plates width [B].

Link Pin Outside Diameter

Standard:

5.3

∼

5.7 mm (0.21

∼

0.22 in.)

Link Plates Outside Width

Standard:

17.35

∼

17.50 mm (0.683

∼

0.689 in.)

If the reading exceeds the specified length, cut and rejoin
the chain again.

•

Check the movement of the rollers.

•

Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment in the Periodic Mainte-
nance chapter).

•

Install the removed parts (see appropriate chapters).

FINAL DRIVE 11-11

Sprocket, Coupling

Engine Sprocket Removal

•

Remove:

Shift Lever [A] (see Shift Pedal Removal in the Crank-
shaft/Transmission chapter)
Engine Sprocket Cover Bolts [B]
Engine Sprocket Cover [C]

•

Remove the speed sensor mounting bracket upper bolts
[A] and lower bolt [B].

•

Remove the speed sensor mounting bracket [C] and
dowel pins.

•

Flatten out the bended washer [A].

•

Remove the engine sprocket nut [B] and washer.

NOTE

○

When loosening the engine sprocket nut, hold the rear
brake on.

•

Raise the rear wheel off the ground with the stand.

•

Loosen the drive chain (see Drive Chain Slack Adjust-
ment in the Periodic Maintenance chapter).

•

Pull the engine sprocket [A] with drive chain [B] off the
output shaft [C].

•

Disengage the drive chain from the engine sprocket.

Engine Sprocket Installation

•

Replace the sprocket washer and axle cotter pin.

•

Install the engine sprocket so that protruding side [A]
faces inside.

•

Apply molybdenum disulfide oil solution to the threads of
output shaft and the surface of washer.

•

Tighten:

Torque - Engine Sprocket Nut: 127 N·m (13.0 kgf·m, 93.7

ft·lb)

NOTE

○

Tighten the nut while applying the rear brake.

•

Bend the one side of the washer over the nut.

11-12 FINAL DRIVE

Sprocket, Coupling

•

Install the dowel pins [A].

•

Install the speed sensor bracket [B] so that the dowel pins
fits into the holes [C] of the speed sensor bracket.

•

Tighten:

Torque - Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Run the speed sensor lead correctly (see Cable, Wire,
and Hose Routing section in the Appendix chapter).

•

Install the engine sprocket cover.

•

Tighten:

Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Adjust the drive chain slack after installing the engine
sprocket (see Drive Chain Slack Adjustment in the Pe-
riodic Maintenance chapter).

•

Install the removed parts (see appropriate chapters).

Rear Sprocket Removal

•

Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).

NOTICE

Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

•

Remove:

Rear Sprocket Nuts [A]
Rear Sprocket [B]

Rear Sprocket Installation

•

Install the sprocket facing the tooth number marking [A]
outward.

•

Replace the rear sprocket nuts with new ones.

•

Tighten:

Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

•

Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).

Coupling Installation

•

Apply grease to the following.

Coupling Grease Seal Lips [A]
Coupling Internal Surface [B]
Ball Bearing [C]

FINAL DRIVE 11-13

Sprocket, Coupling

•

Replace the O-ring [A] with a new one and apply grease
to it.

•

Install:

O-ring
Collar [B]
Coupling

Coupling Bearing Removal

•

Remove:

Coupling
Grease Seal

•

Remove the bearing [A] by tapping from the wheel side.

Special Tool - Bearing Driver Set [B]: 57001-1129

Coupling Bearing Installation

•

Replace the bearing with a new one.

•

Press in the bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

○

Pack the bearing with high-temperature grease.

•

Replace the grease seal with a new one.

•

Press in the grease seal so that the seal surface is flush
with the end of the hole.

○

Apply high-temperature grease to the grease seal lips.

Special Tool - Bearing Driver Set: 57001-1129

Coupling Bearing Inspection

Since the coupling bearing is made to extremely close

tolerances, the clearance can not normally be measured.

NOTE

○

It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.

•

Turn the bearing in the coupling back and forth [A] while
checking for plays, roughness or binding.
If the bearing play, roughness or binding is found, replace
the bearing.

11-14 FINAL DRIVE

Sprocket, Coupling

Coupling Bearing Lubrication

•

Pack the bearing with grease. Turn the bearing around by
hand a few times to make sure the grease is distributed
uniformly inside the bearing.

Coupling Damper Inspection

•

Remove the rear wheel coupling, and inspect the rubber
dampers [A].

•

Replace the damper if it appears damaged or deterio-
rated.

Sprocket Wear Inspection

•

Visually inspect the engine and rear sprocket teeth for
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).

Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]

NOTE

○

If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.

Rear Sprocket Warp Inspection

•

Raise the rear wheel off the ground with the stand so that
it will turn freely.

•

Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.

Rear Sprocket Warp

Standard:

TIR 0.4 mm (0.016 in.) or less

Service Limit: TIR 0.5 mm (0.020 in.)

BRAKES 12-1

Brakes

Table of Contents

Exploded View .......................................................................................................................

12-4

Specifications ........................................................................................................................

12-12

Special Tools ..........................................................................................................................

12-13

Brake Pedal ............................................................................................................................

12-14

Brake Pedal Position Inspection ......................................................................................

12-14

Brake Pedal Position Adjustment .....................................................................................

12-14

Brake Pedal Removal .......................................................................................................

12-14

Brake Pedal Installation ....................................................................................................

12-15

Calipers ..................................................................................................................................

12-16

Front Caliper Removal ......................................................................................................

12-16

Rear Caliper Removal.......................................................................................................

12-16

Caliper Installation ............................................................................................................

12-16

Front Caliper Disassembly................................................................................................

12-17

Front Caliper Assembly.....................................................................................................

12-17

Rear Caliper Disassembly ................................................................................................

12-17

Rear Caliper Assembly .....................................................................................................

12-17

Caliper Fluid Seal Damage Inspection..............................................................................

12-17

Caliper Dust Seal Damage Inspection ..............................................................................

12-17

Caliper Boots Inspection ...................................................................................................

12-17

Caliper Piston and Cylinder Damage Inspection ..............................................................

12-18

Caliper Holder Pin Inspection ...........................................................................................

12-18

Brake Pads .............................................................................................................................

12-19

Brake Pad Removal ..........................................................................................................

12-19

Brake Pad Installation .......................................................................................................

12-19

Brake Pad Wear Inspection ..............................................................................................

12-19

Master Cylinder ......................................................................................................................

12-20

Front Master Cylinder Removal ........................................................................................

12-20

Front Master Cylinder Installation .....................................................................................

12-20

Rear Master Cylinder Removal.........................................................................................

12-20

Rear Master Cylinder Installation......................................................................................

12-21

Front Master Cylinder Disassembly ..................................................................................

12-21

Rear Master Cylinder Disassembly...................................................................................

12-21

Master Cylinder Assembly ................................................................................................

12-21

Master Cylinder Inspection ...............................................................................................

12-22

Brake Disc ..............................................................................................................................

12-23

Brake Disc Removal .........................................................................................................

12-23

Brake Disc Installation ......................................................................................................

12-23

Brake Disc Wear Inspection..............................................................................................

12-23

Brake Disc Warp Inspection..............................................................................................

12-23

Brake Fluid .............................................................................................................................

12-24

Brake Fluid Level Inspection.............................................................................................

12-24

Brake Fluid Change ..........................................................................................................

12-24

Brake Line Bleeding..........................................................................................................

12-24

Brake Hose.............................................................................................................................

12-27

Brake Hose Removal/Installation......................................................................................

12-27

Brake Hose Inspection......................................................................................................

12-27

Anti-Lock Brake System (Equipped Models) ..........................................................................

12-28

Parts Location ...................................................................................................................

12-28

ABS Servicing Precautions ...............................................................................................

12-31

ABS Troubleshooting Outline............................................................................................

12-33

12-2 BRAKES

Inquiries to Rider...............................................................................................................

12-36

Self-diagnosis Outline .......................................................................................................

12-38

Self-diagnosis Procedures ................................................................................................

12-38

Service Code Clearing Procedures...................................................................................

12-39

How to Read Service Codes.............................................................................................

12-42

How to Erase Service Codes ............................................................................................

12-42

Yellow ABS Indicator Light (LED) Inspection ....................................................................

12-44

ABS Unit Solenoid Valve Inspection (Service Code 13, 14, 17, 18) .................................

12-47

ABS Solenoid Valve Relay Inspection (Service Code 19) ................................................

12-47

Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code 25) .............

12-47

ABS Motor Inspection (Service Code 35) .........................................................................

12-48

Wheel Rotation Sensor Signal Abnormal Inspection (Front: Service Code 42) (Rear:

Service Code 44) ...........................................................................................................

12-48

Front or Rear Wheel Rotation Sensor Wiring Inspection (Service Code 43) ....................

12-49

Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)..................................

12-51

Power Supply Voltage Abnormal Inspection (Service Code 52: Low Voltage) (Service

Code 53: High Voltage)..................................................................................................

12-53

ABS Hydraulic Unit Internal Error Inspection (Service Code 55) ......................................

12-54

ABS Hydraulic Unit Removal ............................................................................................

12-55

ABS Hydraulic Unit Installation .........................................................................................

12-56

ABS Hydraulic Unit Inspection ..........................................................................................

12-56

Front Wheel Rotation Sensor Removal ............................................................................

12-57

Front Wheel Rotation Sensor Installation .........................................................................

12-57

Rear Wheel Rotation Sensor Removal .............................................................................

12-58

Rear Wheel Rotation Sensor Installation ..........................................................................

12-58

Wheel Rotation Sensor Inspection....................................................................................

12-59

Wheel Rotation Sensor Air Gap Inspection ......................................................................

12-59

Wheel Rotation Sensor Rotor Inspection..........................................................................

12-59

Fuse Removal...................................................................................................................

12-60

Fuse Installation................................................................................................................

12-60

Fuse Inspection.................................................................................................................

12-60

BRAKES 12-3

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12-4 BRAKES

Exploded View

EX300A Model

BRAKES 12-5

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Brake Hose Banjo Bolts

2.5

Front Brake Reservoir Cap Screws

1.5

0.15

13 in·lb

Brake Lever Pivot Bolt

5.9

0.60

52 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Bleed Valve

5.5

0.56

49 in·lb

Front Brake Pad Pins

17.2

1.75

12.7

Front Caliper Holder Pin Nut

2.2

10 Front Caliper Holder Pin

17.2

1.75

12.7

11 Front Caliper Mounting Bolts

2.5

12 Front Brake Disc Mounting Bolts

2.8

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).

12-6 BRAKES

Exploded View

EX300A Model

BRAKES 12-7

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Rear Master Cylinder Mounting Bolts

2.5

Brake Pedal Bolt

8.8

0.90

78 in·lb

Rear Master Cylinder Push Rod Locknut

17.2

1.75

12.7

Brake Hose Banjo Bolts

2.5

Rear Brake Pad Pins

17.2

1.75

12.7

Bleed Valve

5.5

0.56

49 in·lb

Rear Caliper Holder Pin Nut

2.2

Rear Caliper Holder Pin

17.2

1.75

12.7

Rear Caliper Mounting Bolts

2.5

10 Rear Brake Disc Mounting Bolts

2.8

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease (ex. PBC grease).

12-8 BRAKES

Exploded View

EX300B Model

BRAKES 12-9

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Brake Hose Banjo Bolts

2.5

Front Brake Reservoir Cap Screws

1.5

0.15

13 in·lb

Brake Lever Pivot Bolt

5.9

0.60

52 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Wheel Rotation Sensor Bolt

9.8

1.0

87 in·lb

Brake Pipe Joint Nuts

1.8

Bleed Valve

5.5

0.56

49 in·lb

10 Front Brake Pad Pins

17.2

1.75

12.7

11 Front Caliper Holder Pin Nut

2.2

12 Front Caliper Holder Pin

17.2

1.75

12.7

13 Front Caliper Mounting Bolts

2.5

14 Front Brake Disc Mounting Bolts

2.8

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).

NOTE

○

When disassembling the brake hose and pipe, disassemble them by the unit as shown in the
exploded view.

12-10 BRAKES

Exploded View

EX300B Model

BRAKES 12-11

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Rear Master Cylinder Mounting Bolts

2.5

Brake Pedal Bolt

8.8

0.90

78 in·lb

Rear Master Cylinder Push Rod Locknut

17.2

1.75

12.7

Brake Pipe Joint Nuts

1.8

Brake Hose Banjo Bolts

2.5

Rear Brake Pad Pins

17.2

1.75

12.7

Bleed Valve

5.5

0.56

49 in·lb

Rear Caliper Holder Pin Nut

2.2

Rear Caliper Holder Pin

17.2

1.75

12.7

10 Rear Caliper Mounting Bolts

2.5

11 Rear Wheel Rotation Sensor Bolt

9.8

1.0

87 in·lb

12 Rear Brake Disc Mounting Bolts

2.8

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease (ex. PBC grease).

NOTE

○

When disassembling the brake hose and pipe, disassemble them by the unit as shown in the
exploded view.

12-12 BRAKES

Specifications

Item

Standard

Service Limit

Brake Lever, Brake Pedal

Brake Lever Position

Non-adjustable

– – –

Brake Lever Free Play

Non-adjustable

– – –

Pedal Free Play

Non-adjustable

– – –

Pedal Position

About 40 mm (1.57 in.) below top of footpeg

– – –

Brake Pads

Lining Thickness:

Front (EX300A Model)

4.5 mm (0.18 in.)

1.5 mm (0.06 in.)

Front (EX300B Model)

4.5 mm (0.18 in.)

1 mm (0.04 in.)

Rear

4.5 mm (0.18 in.)

1.5 mm (0.06 in.)

Brake Discs

Thickness:

Front

4.3

∼

4.7 mm (0.17

∼

0.19 in.)

4.0 mm (0.16 in.)

Rear

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

4.5 mm (0.18 in.)

Runout

TIR 0.15 mm (0.006 in.) or less

TIR 0.3 mm (0.01 in.)

Brake Fluid

Grade:

Front

DOT3 or DOT4

– – –

Rear

DOT4

– – –

ABS (Equipped Models)

Wheel Rotation Sensor
Air Gap:

Front

0.1

∼

1.5 mm (0.004

∼

0.060 in.)

– – –

Rear

0.1

∼

1.5 mm (0.004

∼

0.060 in.)

– – –

BRAKES 12-13

Special Tools

Jack:
57001-1238

Hand Tester:
57001-1394

Jack Attachment:
57001-1608

12-14 BRAKES

Brake Pedal

Brake Pedal Position Inspection

•

Check that the brake pedal [A] is in the correct position.

Footpeg [B]

Pedal Position

Standard:

About 40 mm (1.57 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

78 ±1 mm (3.07 ±0.04 in.)

, the

pedal position will be within the standard range.

•

Tighten:

Torque - Rear Master Cylinder Push Rod Locknut: 17.2 N·m

(1.75 kgf·m, 12.7 ft·lb)

•

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

Brake Pedal Removal

•

Remove the right front footpeg bracket bolts [A].

•

Turn the right front footpeg bracket [B] inside out.

•

Remove:

Cotter Pin [A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]

•

Remove the brake pedal bolt [E] and brake pedal [F].

BRAKES 12-15

Brake Pedal

Brake Pedal Installation

•

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

•

Install:

Brake Pedal [C]
Washer [D]

•

Tighten:

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

•

Hook:

Rear Brake Light Switch Spring
Return Spring [F]

•

Replace the cotter pin with a new one.

•

Insert the joint pin from the outside.

•

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

•

Install the right front footpeg bracket, and tighten the bolts.

Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

•

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

12-16 BRAKES

Calipers

Front Caliper Removal

•

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

•

Remove the caliper mounting bolts [B] and caliper [C].

•

Remove the banjo bolt to disconnect the brake hose [D]
from the caliper (see Brake Hose Removal/Installation).

NOTICE

Immediately wash away any brake fluid that spills.

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.

•

Remove the caliper mounting bolts [B] and caliper [C].

•

Remove the banjo bolt and disconnect the brake hose [D]
from the caliper (see Brake Hose Removal/Installation).

NOTICE

Immediately wash away any brake fluid that spills.

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: 25 N·m (2.5 kgf·m, 18 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.

WARNING

After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.

BRAKES 12-17

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 Inspection

The fluid seals (piston seals) [A] are placed around the

piston 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 temperature 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.

Caliper Dust Seal Damage Inspection

•

Check that the dust seals [A] are not cracked, worn,
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.

Pistons [B]
Fluid Seals [C]

Caliper Boots Inspection

•

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.

12-18 BRAKES

Calipers

Caliper Piston and Cylinder Damage Inspection

•

Visually inspect the pistons [A] and cylinder surfaces [B].
Replace the caliper if the cylinder and piston are badly
scores or rusty.

Caliper Holder Pin Inspection

The caliper body must slide smoothly on the caliper holder

pins [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 pins are not badly
worn or stepped, and that the rubber boots are not dam-
aged.

If the caliper holder pin is damage, inspect the caliper
holder for warp or deformation. If the caliper holder is in
good condition, replace the caliper holder pins [A] [B].

Torque - Caliper Holder Pin: 17.2 N·m (1.75 kgf·m, 12.7 ft·lb)

○

Apply a non-permanent locking agent to the threads of
the caliper holder pin nut [C].

Torque - Caliper Holder Pin Nut: 22 N·m (2.2 kgf·m, 16 ft·lb)

BRAKES 12-19

Brake Pads

Brake Pad Removal

NOTE

○

The procedure to remove the front brake pad is as fol-
lows. Removing the rear brake pad is the same as for
the front brake pad.

•

Loosen the pad pins [A].

•

Remove the caliper mounting bolts [B].

•

Remove the caliper with the hose installed.

•

Remove:

Pad Pins
Brake Pads [A]

Brake Pad Installation

NOTE

○

The procedure to install the front brake pad is as follows.
Installing the rear brake pad is the same as for the front
brake pad.

•

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

•

Install the pad spring [A] in its correct position.

•

Install the pad on the piston side first, then install the other
side pad on the holder.

•

Insert the pad pins.

•

Install the caliper (see Caliper Installation).

•

Tighten:

Torque - Brake Pad Pins: 17.2 N·m (1.75 kgf·m, 12.7 ft·lb)

WARNING

Brake Pad Wear Inspection

•

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

12-20 BRAKES

Master Cylinder

Front Master Cylinder Removal

•

Remove the banjo bolt [A] to disconnect the brake hose
from the master cylinder (see Brake Hose Removal/In-
stallation).

•

Remove the clamp bolts [B] and remove the master cylin-
der [C] with the reservoir, brake lever, and brake switch
as an assembly.

•

Disconnect the front brake light switch connector [D].

NOTICE

Immediately wash away any brake fluid that spills.

Front Master Cylinder Installation

•

Connect the front brake light switch connector.

•

Set the front master cylinder to match its mating surface
[A] to the punch mark [B] of the handlebar.

•

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

•

Tighten the upper clamp bolt first, and then the lower
clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Replace the washers that are on each side of the hose
fitting with new ones.

•

Tighten:

Torque - Brake Hose Banjo Bolts: 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.

Rear Master Cylinder Removal

•

Loosen the brake hose banjo bolt [A] and rear master
cylinder mounting bolts [B].

•

Remove the right front footpeg bracket bolts [C].

•

Turn the right front footpeg bracket [D] inside out.

•

Remove:

Cotter Pin [A]
Joint Pin [B]
Rear Master Cylinder Mounting Bolts [C]
Brake Hose Banjo Bolt [D]
Rear Master Cylinder [E]

•

Slide the clamp [F] and disconnect the reservoir hose [G]
from the rear master cylinder.

•

Drain the brake fluid into a container.

BRAKES 12-21

Master Cylinder

Rear Master Cylinder Installation

•

Connect the reservoir hose to the rear master cylinder and
hold it with the clamp.

•

Replace the washers that are on each side of hose fitting
with new ones.

•

Tighten:

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

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

ft·lb)

•

Replace the cotter pin with a new one.

•

Insert the joint pin from the outside.

•

Insert the cotter pin and bend the pin ends.

•

Install the right front footpeg bracket, and tighten the bolts.

Torque - Front Footpeg Bracket Bolts: 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.

12-22 BRAKES

Master Cylinder

Master Cylinder Inspection

•

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

•

Disassemble the front and rear master cylinders (see
Master Cylinder Rubber Parts Replacement in the Peri-
odic Maintenance chapter).

•

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.

•

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.

Front Master Cylinder [J]
Rear Master Cylinder [K]

BRAKES 12-23

Brake Disc

Brake Disc Removal

•

Remove the wheels (see Front/Rear Wheel Removal in
the Wheels/Tires chapter).

•

Remove the mounting bolts and disc.

Brake Disc Installation

•

Install the brake disc on the wheel so that the marked side
[A] faces out.

•

Apply a non-permanent locking agent to the threads of the
front and rear brake disc mounting bolts [B], and tighten
them.

Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear Inspection

•

Measure the thickness of each disc [A] at the point where
it has worn the most.
If the disc has worn past the service limit, replace it.

Measuring Area [B]

Brake Discs Thickness

Standard:

Front

4.3

∼

4.7 mm (0.17

∼

0.19 in.)

Rear

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

Service Limit:

Front

4.0 mm (0.16 in.)

Rear

4.5 mm (0.18 in.)

Brake Disc Warp Inspection

•

Raise the front/rear wheel off the ground.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

○

For front disc inspection, turn the handlebar fully to one
side.

•

Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.

Disc Runout

Standard:

TIR 0.15 mm (0.006 in.) or less

Service Limit:

TIR 0.3 mm (0.01 in.)

12-24 BRAKES

Brake Fluid

Brake Fluid Level Inspection

•

Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.

Brake Fluid Change

•

Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.

Brake Line Bleeding

The brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.

WARNING

Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake lever or pedal has a soft or
"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.

NOTE

○

The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.

•

Remove the reservoir cap [A] and diaphragm.

•

Fill the reservoir with fresh brake fluid to the upper level
line in the reservoir.

Brake Fluid Grade

Front:

DOT3 or DOT4

Rear:

DOT4

•

Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.

○

Bleed the air completely from the master cylinder by this
operation.

•

Remove the rubber cap from the bleed valve [A] on the
caliper.

•

Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.

BRAKES 12-25

Brake Fluid

•

Bleed the brake line and the caliper.

○

Repeat this operation until no more air can be seen com-
ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while holding

the brake applied.

3. Release the brake [C].

NOTE

○

The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.

○

Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.

•

Remove the clear plastic hose.

•

Install the diaphragm and reservoir cap.

•

Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

•

Follow the procedure below to install the rear brake fluid
reservoir cap correctly.

○

First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].

•

Tighten the bleed valve, and install the rubber cap.

Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)

•

Check the fluid level (see Brake Fluid Level Inspection in
the Periodic Maintenance chapter).

•

After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.

12-26 BRAKES

Brake Fluid

WARNING

When working with the disc brake, observe the pre-
cautions listed below.

•

Never reuse old brake fluid.

•

Do not use fluid from a container that has been left
unsealed or that has been open for a long time.

•

Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to dete-
riorate.

•

Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.

•

Don’t change the fluid in the rain or when a strong
wind is blowing.

•

Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillate will cause de-
terioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.

•

When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on
the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned satisfactorily.

•

Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up im-
mediately.

•

If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.

BRAKES 12-27

Brake Hose

Brake Hose Removal/Installation

•

Refer to the Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter.

Brake Hose Inspection

•

Refer to the Brake Hose and Pipe Damage and Instal-
lation Condition Inspection in the Periodic Maintenance
chapter.

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