Brake Control System and Diagnosis: 4A-3
Diagnostic Information and Procedures
Brake Symptom Diagnosis
BA02J24104001
Repair Instructions
Brake Pedal Height Inspection and Adjustment
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Refer to “Brake System Inspection” in Section 0B
(Page 0B-22).
Brake Fluid Level Check
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Refer to “Brake System Inspection” in Section 0B
(Page 0B-22).
Brake Hose Inspection
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Refer to “Brake System Inspection” in Section 0B
(Page 0B-22).
Air Bleeding from Brake Fluid Circuit
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Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full
braking performance of the brake caliper. The presence
of air is indicated by “sponginess” of the brake lever and
also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider, it
is essential that after remounting the brake and restoring
the brake system to the normal condition, the brake fluid
circuit be purged of air in the following manner:
CAUTION
!
Handle brake fluid with care: the fluid reacts
chemically with paint, plastic, rubber
materials, etc.
Front Brake
1) Remove the reservoir cap (1) and diaphragm.
Condition Possible cause Correction / Reference Item
Insufficient brake power Leakage of brake fluid from hydraulic
system.
Repair or replace.
Worn pads and disc. Replace.
Oil adhesion on friction surface of pads. Clean disc and pads.
Air in hydraulic system. Bleed air.
Not enough brake fluid in the reservoir. Replenish.
Brake squeaking Carbon adhesion on pad surface. Repair surface with sandpaper.
Tilted pad. Correct pad fitting or replace.
Damaged wheel bearing. Replace.
Loose front wheel axle or rear wheel
axle.
Tighten to specified torque.
Worn pads and disc. Replace.
Foreign material in brake fluid. Replace brake fluid.
Clogged return port of master cylinder. Disassemble and clean master cylinder.
Excessive brake lever
stroke
Air in hydraulic system. Bleed air.
Insufficient brake fluid. Replenish fluid to specified level; bleed air.
Improper quality of brake fluid. Replace with correct fluid.
Leakage of brake fluid Insufficient tightening of connection
joints.
Tighten to specified torque.
Cracked hose. Replace.
Worn piston and/or cup. Replace piston and/or cup.
Worn piston seal and dust seal. Replace piston seal and dust seal.
Brake drags Rusty part. Clean and lubricate.
Insufficient brake lever or brake pedal
pivot lubrication.
Lubricate.
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IA02J1410002-01
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