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,

WARNING

Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.

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.

WARNING

Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.

• 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.

WARNING

Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done.

• 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

CAUTION

Immediately wash away any brake fluid that spills.

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

○Pulloff 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]

 

 

Brake Disc

Brake Disc Removal

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

• Unscrew the mounting bolts, and take off the disc.

• Remove the gaskets.

Brake Disc Installation

• Replace the gaskets with new ones.

• 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].

• Tighten:

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

ft·lb)

Brake Disc Wear

• 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:

EX650A Models 4.3 ~ 4.7 mm (0.17 ~ 0.19 in.)

EX650B Models 4.8 ~ 5.2 mm (0.19 ~ 0.20 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

• Raise the wheel off the ground with jack (see Front/Rear Wheel Removal in the Wheels/Tires chapter).