Hydraulic Brake

SERVICE INFORMATION

15-2

FRONT MASTER CYLINDER

15-10

TROUBLESHOOTING

15-3

REAR MASTER CYLINDER

15-15

BRAKE FLUID REPLACEMENT/

FRONT BRAKE CALIPER

15-19

AIR BLEEDING

15-4

REAR BRAKE CALIPER

15-23

BRAKE PAD/DISC

15-7

BRAKE PEDAL

REAR:

SERVICE INFORMATION

GENERAL

A CAUTION

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.

• Avoid breathing dust particles.

• Never use an air hose or brush to clean brake assemblies. Use and OSHA-approved vacuum cleaner.

• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake digreasing agent.

• Check the brake system by applying the brake lever or pedal after the air bleeding.

• Spilled hrake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Re careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.

• Never allow contaminates (dirt, water, etc.) to get into an open reservoir.

• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.

• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid they may not be compatible.

• Always check brake operation before riding the motorcycle.

SPECIFICATIONS

Front

Rear

ITEM

STANDARD

SERVICE LIMIT

Specified brake fluid

DOT 4

-

Brake disc thickness

4.4-4.6 (0.17-0.18)

3.5 (0.14)

Brake disc runout

-

0.20 (0.008)

Master cylinder I.D.

15.870 15.913 (0.6248 - 0.6265)

15.925 (0.6270)

Master piston O.D.

15.827 15.854 (0.6231 0.6242)

15.815 (0.6226)

Caliper cylinder I.D.

A

33.96-34.01 (1.337 1.339)

34.02 (1.339)

n

32.030-32.080 (1.2610- 1.2630)

32.09 (1.263)

Caliper piston O.D.

A

33.802 - 33.835 (1.3308 - 1.3321)

33.794 (1.3305)

B

31.877 - 31.910 (1.2550 - 1.2563)

31.869 (1.2547)

Specified brake fluid

DOT 4

-

Brake pedal height

75 (3.0)

-

Brake disc thickness

4.8-5.2 (0.19-0.20)

4.0 (0.16)

Brake disc runout

-

0.30 (0.012)

Master cylinder I.D.

14.000 - 14.043 (0.5512 -0.5529)

14.055 (0.5533)

Master piston O.D.

13.957 - 13.984 (0.5495 -0.5506)

13.945 (0.5490)

Caliper cylinder I.D.

38.18 -38.23(1.053- 1.505)

38.24 (1.506)

Caliper piston O.D.

38.098 - 38.148 (1.4999 - 1.5019)

38.09 (1.500)

TORQUE VALUES

front master cylinder reservoir cap screw

Broke lever pivot bolt

Brake lever pivot nut

Front brake light switch screw

Front master cylinder mounting bolt

Front brake caliper assembly torx bolt

Front brake caliper mounting flange bolt

Rear master cylinder joint nut

Rear master cylinder mounting bolt

Rear brake reservoir mounting bolt/nut

Rear brake caliper bracket holt

Rear brake caliper pin bolt

Pad pin

Pad pin plug

Brake hose oil bolt

Brake caliper bleeder valve

TOOL

Snap ring pliers

TROUBLESHOOTING

Brake lever/pedal soft or spongy

• Air in hydraulic system

• I eaking hydraulic system

• Contaminated brake pad/disc

• Worn caliper piston seal

• Worn master cylinder piston cups

• Contaminated caliper

• Rear caliper not sliding properly

• Low brake fluid level

• Clogged fluid passage

• Warped/deformed brake disc

• Sticking/worn caliper piston

• Sticking/worn master cylinder piston

• Contaminated master cylinder

• Bent brake lever/pedal

Brake lever/pedal hard

• Clogged/restricted brake system

• Sticking/worn caliper piston

• Rear caliper not sliding properly

• Clogged/restricted fluid passage

• Worn caliper piston seal

• Sticking/worn master cylinder piston

• Bent brake lever/pedal

2 N-m (0.2 kgf-m, 1.4 lhf-ft) 1 N-m (0.1 kgf-m, 0.7 lbf-ft) 6 Nun (0.6 kyf-m, 4.3 lbf-ft) 1 N-m (0.1 kgf-m, 0.7 lbf-ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft)

23 N-m (2.3 kgf-m, 17 lbf-ft) Apply a locking agent to the threads. 30 N-m (3.1 kgf-m, 22 lbf-ft) ALOC bolt. 18 N-m (1.8 kgf-m, 13 lbf-ft) 9 N-m (0.9 kgf-m, 6.5 lbf-ft) 12 N-m (1.2 kgf-m, 9 lbf-ft) 23 N-m (2.3 kgf-m, 17 lbf-ft)

27 N-m (2.8 kgf-m, 20 lbf-ft) Apply a locking agent to the threads. 18 N-m (1.8 kgf-m, 13 lbf-ft)

3 N-m (0.3 kgf-m, 2.2 lbf-ft) 34 N-m (3.5 kgf-m, 25 lbf-ft) 6 N-m (0.6 kgf-m, 4.3 lbf-ft)

07914-SA50001

Brake drags

• Contaminated brake pad/disc

• Misaligned wheel

• Clogged/restricted brake hose joint

• Warped/deformed brake disc

• Rear caliper not sliding properly

• Clogged/restricted brake hydraulic system

• Slickiny/worn caliper piston

• Clogged master cylinder port

BRAKE FLUID REPLACEMENT/AIR BLEEDING

NOTICE

• Do not allow foreign material to enter the system when filling the reservoir.

• Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.

BRAKE FLUID DRAINING

For the front brake, turn the handlebar until the reservoir is parallel to the ground, before removing the reservoir cap.

Remove the screws and reservoir cap. Remove the diaphragm plate and diaphragm.

For the rear brake, remove the rear brake reservoir mounting bolt/nut.

Remove the reservoir cap.

RESERVOIR CAP

RESERVOIR CAP

Remove the diaphragm plate and diaphragm.

DIAPHRAGM PLATE

DIAPHRAGM PLATE

DIAPHRAGM

PLATE

PLATE

Connect a bleed hose to the caliper bleed valve.

Loosen the bleed valve and pump the brake lever or pedal.

Stop pumping the lever or pedal when fluid stop flowing out of the bleed valve.

BRAKE FLUID FILLING

Fill the reservoir with DOT 4 brake fluid from a scaled container.

• Use only DOT 4 brake fluid from a sealed container.

• Do not mix different types of fluid, they are not compatible.

Connect a commercially available brake bleeder to the bleed valve.

Pump the brake bleeder and loosen the bleed valve, adding fluid when the fluid level in the master cylinder reservoir is low.

• Check the fluid level often while bleeding the brakes to prevent air from being pumped into the system.

• When using a brake bleeding tool, follow the manufacturer's operating instructions.

Repeat the previous step procedures until air bubbles do not appear in the plastic hose.

• If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape.

• If a brake bleeder is not available, fill the master cylinder and operate the brake lever or pedal to fill the system.

Close the bleed valve.

Next, perform the brake bleeding procedure.

BLEED VALVE BLEED HOSE

BLEED VALVE BLEED HOSE

BRAKE BLEEDER

NOTICE

BRAKE BLEEDING

Connect a clear bleed hose to the bleed valve. Pump the lever or pedal until there are no air bubbles in the fluid flowing out of the master cylinder, and lever or pedal resistance is felt.

Do not release the brake lever or pedal untii the bieed vaive has been closed

Repeat steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleed valve. Tighten the bleed valve.

Fill the fluid reservoir to the upper level. Reinstall the diaphragm and diaphragm plate.

Install the reservoir cap, and tighten the screws to the specified torque.

1. Squeeze the brake lever or push the brake pedal, open the bleed valve 1/2 of a turn and then close the valve.

2. Release the brake lever or pedal until the bleed valve has been closed.

SCREWS

RESERVOIR CAP

Install the reservoir cap securely, then install the reservoir onto the seat rail and tighten the mounting bolt/nut to the specified torque.

RESERVOIR CAP

BRAKE PAD/DISC

/Always replace FRONT BRAKE PAD REPLACEMENT

the bmke pads in pairs to assure Loosen the pad pins. even disc n^s- Remove the bolts and brake caliper.

sure.

Check the urake fluid level in the brake master cylinder reservoir as this operation causes the level to nse.

Push the caliper pistons all the way in to allow installation of new brake pads.

Remove the pad pins, pad spring and brake pads.

Clean the inside of the caliper especially around the caliper pistons.

PAD PINS

Brake Fluid Bike

BRAKE CALIPER

PAD PINS

BRAKE CALIPER

BRAKE PADS

PAD SPRING

Install the new brake pads.

Install the pad spring with its arrow mark facing up as shown.

Push the pad spring, then install the pad pin.

Be careful not:o Install the brake caliper to the fork leg so that the disc Carriage The pads, is positioned between the pads.

Install and tighten the new brake caliper mounting bolts.

Tighten the pad pins.

REAR BRAKE PAD REPLACEMENT

Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise.

Push the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads.

Always replace the Cake pads in pairs io assure even disc pros sure

Remove the pad pin plug.

RRAKE PADS

ARROW MARK

PAD PINS

BRAKE CALIPrn

PAD PINS

BRAKE CALIPrn

PAD PIN PLUG

Loosen the pad pin.

Remove the caliper bracket bolt.

Pivot the caliper up.

Remove the pad pin and brake pads.

Make sure the brake pad spring is in place. Install the new brake pads.

Lower the caliper while pushing the pads against the pad spring so the pad ends arc positioned onto the retainer on the caliper bracket.

Install the pad pin.

Install and tighten the caliper bracket bolt. TORQUE: 23 N-m (2.3 kgf-m, 17 lbf-ft) Tighten the pad pin. TORQUE: 18 N-m (1.8 kgf-m, 13 lbf-ft)

CALIPER BRACKET BOLT

BRAKE PADS

PAD PIN

Install and tighten the pad pin plug. TORQUE: 3 N-m (0.3 kgf-m, 2.2 lbf-ft)

PAD PIN

Visually inspect the brake disc for damage or cracks.

Measure the brake disc thickness with a micrometer.

BRAKE DISC INSPECTION

SERVICE LIMITS:

Replace the brake disc if the smallest measurement is less than the service limit.

Measure the brake disc warpage with a dial indicator.

SERVICE LIMITS:

Check the wheel bearings for excessive play, if the worpage exceeds the service limit. Replace the brake disc if the wheel bearings are normal.

FRONT MASTER CYLINDER

REMOVAL

Drain the front hydraulic system (page 15-4).

Disconnect the brake light switch wire connectors. Avoid spilling fluid Remove the brake hose oil bolt, sealing washers and un painted, brake hose eyelet.

plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.

SEALING WASHERS OIL BOLT

Remove the bolts from the master cylinder holder and MASTER CYLINDER remove the master cylinder assembly.

HOLDER

HOLDER

BOLTS

BOLTS

DISASSEMBLY

Remove the pivot bolt/nut and brake lever assembly.

BRAKE LEVER

PIVO'I NUT

BRAKE LEVER

PIVO'I NUT

Remove the screw and brake light switch.

SCREW BRAKE LIGHT SWITCH

SCREW BRAKE LIGHT SWITCH

Remove the boot.

BOOT

BOOT

Remove the snap ring from the master cylinder body using the special tool as shown.

TOOL:

Snap ring pliers 07914-SA50000

Remove the master piston and spring.

Clean the inside of the cylinder and reservoir with brake fluid.

MASTER PISTON

MASTER CYLINDER

MASTER PISTON

MASTER CYLINDER

PISTON CUPS SPRING

INSPECTION

Check the piston boot, primary cup and secondary cup for fatigue or damage.

Check the master cylinder and piston for abnormal scratches.

Measure the master cylinder I.D. SERVICE LIMIT: 15.925 mm (0.6270 in)

Measure the master cylinder piston O.D. SERVICE LIMIT: 15.81b mm (0.6226 in)

SNAP RING SNAP HING PLIERS

SNAP RING SNAP HING PLIERS

ASSEMBLY

1 N-m (0.1 kgf-m, 0.7 lbf-ft)

Keep the piston, cups, spring, snap ring and boot as a set do not substitute individual oarts.

When installing the cups, do not allow the hps to lum inside out.

Coat all parts with clean brake fluid before assembly. MASTER PISTON

MASTER CYLINDER

Dip the piston in brake fluid.

Install the spring into the piston.

Install the piston assembly into the master cylinder.

MASTER CYLINDER

PISTON CUPS SPRING

Be certain the Install the snap ring. snap ring is firmly seated in the JOOL:

groove. Snap r|ng p||ers 07914-SA50000

SNAP RING SNAP RING PLIERS

SNAP RING SNAP RING PLIERS

Install the boot.

BOOT

BOOT

SCREW BRAKE LIGHT SWITCH

/ BRAKE LEVER

Install the brake light switch and tighten the screw to the specified torque.

SCREW BRAKE LIGHT SWITCH

Apply silicone grease to the contact surfaces of the brake lever and piston tip.

Install the brake lever assembly, tighten the pivot bolt to the specified torque.

Hold the pivot bolt and tighten the pivot nut to the specified torque.

/ BRAKE LEVER

Place the master cylinder assembly on the handlebar. Align the end of the master cylinder with the punch mark on the handlebar.

Install the master cylinder holder with the "UP" mark facing up.

Tighten the upper holt first, then the lower holt to the specified torque.

MASTER CYLINDER

HOLDER

MASTER CYLINDER

HOLDER

"UP" MARK

BOLTS

"UP" MARK

BOLTS

Install the brake hose eyelet with the oil boll and new sealing washers.

Push the eyelet joint against the stopper, then tighten the oil bolt to the specified torque.

Connect the brake light switch wire connectors.

Fill the reservoir to the upper level and bleed the brake system (page 15-4).

^fc SEALING WASHERS OIL BOLT y^fr n

SWITCH CONNECTORS

SWITCH CONNECTORS

REAR MASTER CYLINDER

REMOVAL

Drain the rear hydraulic system (page 15-4).

Remove the brake light switch wire clamp. Disconnect the brake light switch 2P (Black) connector.

Remove the rear master cylinder reservoir mounting bolt/nut.

BOLT/NUT

BOLT/NUT

BRAKE LIGHT SWITCH CONNECTOR

Avoid spitting fluid Remove the brake hose oil bolt, sealing washers and or, painted, brake hose.

plastic, ui lubbe:

parts P'ace a rag [_ooscn the rear master cylinder mounting bolts.

over these parts Remove lhe ricJer footpeg br acket socket bolts and whenever the . . , , . . , .

Syc-tdm je driver footpeg bracket assembly.

serviced.

FOOTPEG BHACKEI

Remove and discard the brake pedal joint cotter pin. Remove the joint pin.

Remove the master cylinder mounting bolts, step guard and master cylinder.

DISASSEMBLY

Remove the screw and reservoir hose joint from the master cylinder.

Remove the boot.

Remove the snap ring from the master cylinder body using the special tool as shown.

TOOL:

Snap ring pliers 07914-SA50000

Remove the push rod, master piston, primary cup and spring.

Clean the inside of the cylinder with brake fluid.

SPRING PRIMARY CIJP

SPRING PRIMARY CIJP

MASTER PISTON PUSH ROD ASSEMBLY

MASTER CYLINDER

MASTER CYLINDER

JOINT

JOINT

BOOT SNAP RING

PLIERS

BOOT SNAP RING

INSPECTION

Check the piston boot, primary cup and secondary cup for fatigue or damage.

Check the master cylinder and piston tor abnormal scratches.

Measure the master cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5533 in) Measure the master cylinder piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in)

ASSEMBLY

RESERVOIR JOINT

RESERVOIR CAP

O-RING

MASTER CYLINDER

DIAPHRAGM PLATE

PUSH ROD

SPRING

PRIMARY CUP

DIAPHRAGM

MASTER PISTON

SECONDARY CUP .

SNAP RING

LOWER JOINT

BOOT

Keep the piston, cups, spring, snao ring and boot as a set; do not substitute individual pans.

When installing the cups, do not allow jhe lips to turn inside out.

Coat all parts with clean brake fluid hefore assembly.

Dip the piston in brake fluid.

Install the spring onto the primary cup.

Install the spring/primary cup and master piston assemhly.

Apply silicone grease to the piston contact area of the push rod.

SPRING

PRIMARY CUP

SECONDARY CUP

PRIMARY CUP

SECONDARY CUP

MASTER PISTON PUSH ROD ASSEMBLY

MASTER PISTON PUSH ROD ASSEMBLY

Install the push rod into the master cylinder. Be certain the Install the snap ring. snap ring is firmly seated in the TOOL:

groove. Snap ring p|iers 0791A-SA50000

Install the boot.

Apply brake fluid to a new O-ring and install it onto the reservoir joint.

Install the reservoir joint into the master cylinder.

Apply a locking agent to the reservoir joint screw threads.

Install and tighten the screw securely.

If the push rod is disassembled, adjust the push rod length as shown.

After adjustment, tighten the lock nut to the specified torque.

SNAP RING

PLIERS

^Sii B00T

SNAP RING

RESERVOIR

RESERVOIR

RESERVOIR JOINT

RESERVOIR JOINT

LOCK NUT LOWER JOINT

LOCK NUT LOWER JOINT

INSTALLATION

Place the master cylinder onto the main footpeg bracket, install the step guard and master cylinder mounting bolts.

Connect the brake pedal to the push rod lower joint. Install the joint pin and secure it with a new cotter pin.

Install the rider footpeg bracket onto the frame, tighten the socket bolts to the specified torque.

Tighten the master cylinder mounting bolls to the specified torque.

Install the brake hose with the oil bolt and new sealing washers.

Push the eyelet joint against the stopper, then tighten the oil bolt to the specified torque.

Install and tighten the brake reservoir mounting bolt'nut to the specified torque.

Connect the brake light switch 2P (Black) connector. Secure the brake light switch wire with a wire clamp.

Fill the reservoir to the upper level and bleed the brake system (page 15-4).

BOLT/NUT RESERVOIR

BRAKE LIGHT SWITCH CONNECTOR

BRAKE LIGHT SWITCH CONNECTOR

FRONT BRAKE CALIPER

REMOVAL

Avoid spilling fluid on painted, plastic., or njDbar ports. Place s rag over these pans whenever the system is serviced.

Drain the front brake hydraulic system (page 15-4).

Remove the oil bolt, scaling washers and brake hose eyelet joint.

Remove the caliper mounting bolts, caliper and the brake pads (page 15-6).

SEALING WASHERS

OIL BOLT

SEALING WASHERS

OIL BOLT

BRAKE CALIPER

MOUNTING BOLTS

SEALING

WASHERS

FOOTPEG BRACKET

DISASSEMBLY

Install corrugated cardboard or a sheet of soft wood hetween the pistons. Do not use high Apply small squirts of air pressure to the fluid inlet to pressure air or remove the pistons.

bring the nozzle too close to the inlet

PISTON SEAL

ASSEMBLY

Remove the four caliper assembly bolts and separate the caliper halves.

ASSEMBLY

Mark the pistons Remove the following: to ensure correct - Joint seals reassembly. _ Caliper piston A - Caliper piston B

Be careful not to Push the dust seals and piston seals in and lift them damage the out. piston sliding surface, clean the seal grooves with clean brake fluid.

SPAL

PISTON SEAL

CALIPER PISTONS

JOINT

CALIPER PISTONS

JOINT

INSPECTION

Check the caliper cylinder for scoring or damage.

Measure the caliper cylinder I.D.

SERVICE LIMITS:

other

Check the caliper pistons for scratches, scoring or other damage.

Measure the caliper piston O.D.

SERVICE LIMITS:

ASSEMBLY

CALIPER PISTON B

CALIPER PISTON B

Primary Piston Brakes Honda

Coat the new piston seals with clean brake fluid. Coat the new dust seals with silicone grease.

Install the piston and dust seals into the grooves in the caliper body.

Coat the caliper pistons with clean brake fluid and install them into the caliper cylinder with their open ends toward the pad.

Install the new joint seal into the fluid passage on caliper.

CALIPER PISTONS 'X

CALIPER PISTONS 'X

JOINT SEAL

Assemble the caliper halves.

Apply a locking agent to the caliper assembly bolt threads.

Install and tighten the caliper assembly bolts to the specified torque.

INSTALLATION

Install the brake pads and caliper onto the fork leg (page 15-6).

Install and tighten the new caliper mounting bolts to the specified torque.

Install the brake hose eyelet to the caliper body with two new sealing washers and oil bolt.

PISTON SEAL

CALIPER PISTON

PISTON SEAL

ASSEMBLY

ASSEMBLY

Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque.

Fill and bleed the front brake hydraulic system (page 15-4).

STOPPER

OIL BOLT

STOPPER

OIL BOLT

REAR BRAKE CALIPER J

REMOVAL

Drain the rear hrake hydraulic system {page 15-5).

Avoid spiting fluid Remove the oil bolt, sealing washers and brake hose or, painted, eyelet joint.

plastic, or rubber ports. Placcarag Remove the caliper bracket bolt and the brake pads t over these parts (page 15.8). *

whenever the system is serviced

BRACKtl BOL I

BRACKtl BOL I

Pivot the caliper up and remove it.

DISASSEMBLY

Remove the pad spring, collar and boot from the caliper body.

COLLAR

BOOT

BOOT

PAD SPRING

Place a shop towel over the piston. Do nul use high Position the caliper body with the piston down and pressure sir or apply small squirts of air pressure to the fluid inlet to bring tne nozzle remove the piston.

loo close to the inlet be careful not to Push the dust seal and piston seal in and lift them out.

damage the piston sliding clean the seal grooves with clean brake fluid.

surface

PISTON SEAL

PISTON SEAL

INSPECTION

Check the caliper cylinder for scoring or other damage.

Measure the caliper cylinder I.D. SERVICE LIMIT: 38.24 mm (1.506 in)

Check the caliper pistons for scratches, other damage.

Measure the caliper piston O.D. SERVICE LIMIT: 38.09 mm (1.500 in)

ing or

ASSEMBLY

COLLAR

BOOT

BOOT

COLLAR

CALIPER PISTON

DUST SEAL

CALIPER PISTON

DUST SEAL

Coat the new piston seal with clean brake fluid. Coat the new dust seal with silicone grease.

Install the piston seal and dust seal into the groove of the caliper body.

Coat the caliper piston with clean brake fluid and install it into the caliper cylinder with its open end toward the pad.

DUST SEAL

DUST SEAL

PISTON SEAL

CALIPER PISTON

PISTON SEAL

CALIPER PISTON

Install the pad spring into the caliper body. If the caliper and bracket pin boots are hard or deteriorated, replace them with new ones.

Apply silicone grease to the inside of the bracket pin boot.

Install the bracket pin boot and collar into the caliper.

BOOT

PAD SPRING

BOOT

COLLAR

Install the pad retainer into the bracket.

INSTALLATION

Apply silicone grease to the caliper pin and install the caliper onto the bracket.

Install the brake pads (page 15-8).

Install and tighten the caliper bracket bolt to the specified torque.

Install the brake hose eyelet to the caliper body with two new sealing washers and the oil bolt.

Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque.

Fill and bleed the rear brake hydraulic system (page 15 4).

BRAKE PEDAL

REMOVAL

Remove the main footpcg brocket mounting bolts and bracket assembly from the lower bracket.

Remove and discard the brake pedal joint cotter pin Remove the joint pin.

Unhook the return spring and remove the brake light switch from the step holder.

Unhook the brake pedal return spring.

Remove the snap ring, thrust washer and wave washer.

Remove the brake pedal from the pivot.

COTTER PIN SNAP RING

COTTER PIN SNAP RING

BRAKE CALIPER

STOPPER

f BRACKET BOLT

STOPPER

FOOTPEG BRACKET

INSTALLATION

RETURN SPRING

BRAKE LIGHT SWITCH

SWITCH SPRING

COTTER PIN

RETURN SPRING

BRAKE LIGHT SWITCH

SWITCH SPRING

COTTER PIN

RIDER FOOTPEG BRACKET

JOINT PIN SNAP HING WAVE WASHER

THRUST WASHER

BRAKE PEDAL

RIDER FOOTPEG BRACKET

Apply gr ease to the sliding surface of the brake pedal and footpeg.

Install the brake pedal, wave washer and thrust washer to the pedal pivot.

WAVE WASHER

THRUST

WASHER

WAVE WASHER

THRUST

WASHER

BRAKE PEDAL

Secure the pedal pivot with a snap ring.

Hook the brake pedal return spring.

Install the brake light switch and hook the switch spring.

Connect the brake pedal to the push rod lower joint. Install the joint pin and secure it with a new cotter pin.

COTTER PIN SNAP RING

BRAKE PEDAL

COTTER PIN SNAP RING

RETURN SPRING

install the right rider footpeg bracket assembly onto the frame.

Install and tighten the right rider footpeg bracket socket bolts to the specified torque.

FOOTPEG BRACKET

BOLTS

MEMO

SYSTEM DIAGRAM

Cotter Bicycle Diagram

BATTERY

MAIN FUSE 3 OA

GP Black

REGULATOR/RECTIFIER

ALTERNATOR

W: White

ALTERNATOR

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