BRAKE SYSTEM
17-3
SERVICE INFORMATION
GENERAL
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• A contaminated brake disc or pad, brake drum or shoe reduces stopping power. Discard contaminated pads, shoes and
clean a contaminated disc, drum with high quality brake degreasing agent.
• Check the brake system by applying the brake levers after the air bleeding.
• Never allow contaminants (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 3 or 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 scooter.
SPECIFICATIONS
Unit: mm (in)
TORQUE VALUES
Frequent inhalation of brake pad and brake shoe 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.
ITEM STANDARD SERVICE LIMIT
Front disc
brake
Specified brake fluid DOT 3 or DOT 4 –
Brake disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Brake disc warpage – 0.30 (0.012)
Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper cylinder I.D. 27.000 – 27.050 (1.0630 – 1.0650) 27.060 (1.0654)
Caliper piston O.D. 26.918 – 26.968 (1.0598 – 1.0617) 26.910 (1.0594)
Rear drum
brake
Brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)
Brake caliper bleed valve 5.4 N·m (0.55 kgf·m, 4.0 lbf·ft)
Master cylinder reservoir cap screw 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
Brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with a new one.
Brake pad pin 17.2 N·m (1.8 kgf·m, 13 lbf·ft)
Brake pad pin plug 2.4 N·m (0.25 kgf·m, 1.8 lbf·ft)
Front brake light switch screw 1.2 N·m (0.12 kgf·m, 0.9 lbf·ft)
Front brake lever pivot screw 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Front brake lever pivot nut 5.9 N·m (0.60 kgf·m, 4.4 lbf·ft)
Brake master cylinder holder bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Equalizer connecting cable lock nut 6.4 N·m (0.65 kgf·m, 4.7 lbf·ft)
Rear brake lever pivot screw 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Rear brake lever pivot nut 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) U-nut.
Equalizer rod pivot screw 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Equalizer rod pivot nut 4.5 N·m (0.46 kgf·m, 3.3 lbf·ft) U-nut.
Equalizer bracket cover screw 4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)
Equalizer bracket cover special screw 4.2 N·m (0.43 kgf·m, 3.1 lbf·ft) U-nut.
Rear brake arm bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt; replace with a new one.
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