Rear brake control

4 -	Rear brake control

1	Rear brake master cylinder

2

3	Reservoir - master cylinder hose

4	Fluid reservoir

5	Filler cap

6	Sealing washer

7	Banjo bolt

8

9

10

11

12

13	Rear brake hose

14	Brake pedal

15

16

17

18

19

20

21

22

23

24	Adjuster screw

25

26

27

28

Parts catalogue


REAR BRAKE

Important

Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.

Removal of the rear brake master cylinder

Warning

The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical nature of this component. Incorrect overhaul of this component could endanger rider safety.

Maintenance operations on these units are limited to renewal of the following parts: control lever, fluid reservoir assembly and relative fasteners and the complete master cylinder assembly.


Operation	Section reference
Drain the braking system	D 4, Draining the brake circuits

Undo the banjo bolt (7) securing the rear brake hose (13) and recover the sealing washers (6).

Unscrew and remove the bolts (12) securing the rear brake master cylinder (1).

The master cylinder (1) is now free of the footrest bracket.

Release the pin (11) from the return spring (20) and remove the pin after having removed the circlip (17).

Next unscrew the nut (9) and the pushrod (8) from the clevis (10).

Remove the bolt (23) securing the reservoir (4).

Remove the complete master cylinder and the reservoir (4) with the hose (3).

If necessary, remove the footrest bracket as described in Section H 4, Removal of the footrest brackets.

Unscrew the pivot bolt (16).

Remove the pedal (14) and recover the washer (21) and O-rings (19).

If the bush (18) in the footrest bracket is to be renewed, install the new bush using a press so that it is recessed 2 mm relative to the outer surface of the footrest bracket (B).

Refitting the rear brake master cylinder

Warning

After working on the rear brake control, check the operation of the brake pedal following the instructions given in Section D 4, Adjusting the position of the gearchange and rear brake pedals.

Apply the recommended grease to the pivot bolt (16) and the seats of the O-rings (19).

Apply the recommended threadlocker to the thread of the hole for the pivot bolt (16) in the right-hand footrest bracket.

Fit the pivot bolt (16) on the lever (14) with O-rings (19) and washer (21).

Fit the gearchange lever (14) to the footrest bracket and tighten the pivot bolt (16) to the specified torque (Sect. C 3, Frame torque settings).

Notes

When refitting the lever, make sure that the O-rings remain correctly seated.

Fit the spring (20), locating the end in the groove of in the clevis pivot pin (11).

If removed, refit the right-hand footrest bracket as described in Section H 4, Refitting the footrest brackets.

Locate the rear brake master cylinder (1) on the motorcycle and fit the retaining bolts (12), applying the recommended threadlocker.

Tighten the bolts (12) to the specified torque (Sect. C 3, Frame torque settings).

Locate the reservoir (4) on its lug on the frame and secure it with the bolt (23) tightened to the specified torque (Sect. C 3, Frame torque settings).

If the rod (8) - clevis (10) assembly has been dismantled, reassemble by screwing nut (9) onto the rod (8), then screw the rod into the clevis (10) to obtain the measurement indicated in the figure.

Restrain the pushrod and tighten the nut (9) against clevis (10) to the specified torque (Sect. C 3, Frame torque settings).

Lubricate the other end of the rod (8) with the recommended grease and insert it in the master cylinder (1).

Reconnect the hose (13), locating the sealing washers (6) on both sides of the hose end fitting, and secure it with the banjo bolt (7).

Orientate the brake hose end fitting (13) so that is pointing inwards at 90° to the axis of the master cylinder.

Tighten the banjo bolt (7) to the specified torque (Sect. C 3, Frame torque settings).


Operation	Section reference
Fill the brake circuit	D 4, Filling the brake circuits

Positioning of rear brake hose