1.16BRAKE PADS AND DISCS
INSPECTION
Check brake pads and discs:
• At every scheduled service interval.
• Whenever the components are removed during service
procedures.
Brake Pads
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
See Figure 1-33. Replace brake pads (3) if brake pad friction
material on either the front or rear caliper is worn to 0.04
in. (1.02 mm) or less above the backing plate (4). Always
replace both pads in a caliper as a set. See 1.16 BRAKE PADS
AND DISCS, Brake Pad Replacement.
When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage.
Brake Disc Thickness
The minimum brake disc (2) thickness is stamped on the side
of the disc. Replace disc if badly scored.
Brake Disc Lateral Runout and Warpage
Maximum brake disc lateral runout and warpage is 0.008
in. (0.2 mm) when measured near the outside diameter.
1. Front brake caliper (viewed from below)
2. Brake disc
3. Brake pads
4. Backing plate
5. Rear brake caliper (viewed from above)
Figure 1-33. Brake Pad Inspection
BRAKE PAD REPLACEMENT
Rear Brake Caliper
1. If present, remove right saddlebag.
2. Remove the rear master cylinder reservoir cap. As the
pistons are pushed back into the caliper, fluid level may
rise above the recommended 1/8 in. (3.2 mm) below the
gasket surface.You may have to remove fluid to allow for
this.
3. See Figure 1-34. Loosen, but do not remove, pad pin (1)
(metric).
4. Pry the outside pad back until the pistons are completely
retracted. Use steady pressure to prevent scoring the
brake disc. Pry between the pad and the brake disc in
order to push the caliper pistons back into their bores.
1-30 2008 Dyna Service: Maintenance
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