HYDRAULIC BRAKE
17-4
SERVICE INFORMATION
GENERAL
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to same rubber parts. Be
careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• This model is equipped with a Combined Brake System. The system air bleeding procedure on page 17-7 must be fol-
lowed.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• Check the brake system by applying the brake levers after the air bleeding.
• 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 scooter.
• This section covers service of the standard brake components (including CBS) of the brake system. page 18-4 for ABS
service.
• The brake fluid replacement procedure for the ABS model should be performed in the same manner as in the standard
model. Note that there is no brake fluid in the ABS modulator (except in the modulator head), because the modulator is
the motor-driven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body
is not necessary.
SPECIFICATIONS
Unit: mm (in)
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.
ITEM STANDARD SERVICE LIMIT
Front Specified brake fluid DOT 4 –
Brake disc thickness 4.3 – 4.7 (0.17 – 0.19) 3.5 (0.14)
Brake disc warpage – 0.25 (0.010)
Master cylinder I.D. 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352)
Master piston O.D. 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309)
Caliper cylinder I.D. Upper 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)
Middle 22.650 – 22.700 (0.8917 – 0.8937) 22.710 (0.8941)
Lower 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)
Caliper piston O.D. Upper 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
Middle 22.585 – 22.618 (0.8892 – 0.8905) 22.56 (0.888)
Lower 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
Rear Specified brake fluid DOT 4 –
Brake disc thickness 4.8 – 5.2 (0.19 – 0.20) 4.0 (0.16)
Brake disc warpage – 0.25 (0.010)
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 (0.4987)
Caliper cylinder I.D. 38.180 – 38.230 (1.5031 – 1.5051) 38.24 (1.506)
Caliper piston O.D. 38.098 – 38.148 (1.4999 – 1.5019) 38.09 (1.500)
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