Hydraulic front brake

3 -	Hydraulic front brake

1	Pad retaining pin and clip

Bolt

3	Right brake caliper

4	Sealing washer

5	Bleed valve

6	Banjo bolt

Dust cap

8	Calipers–master cylinder hose

9	Pair of brake pads

10	Left brake caliper

Spring

12	Hose guide

13	Brake disc

Bolt

Support

Bolt

Parts catalogue


FRONT AND REAR WHEELS
FRONT 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.

Maintenance operations

Warning

Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In case of accidental contact, wash the affected area with abundant running water and consult a doctor if necessary.

For maintenance instructions (brake pad wear check and renewal, brake fluid change, etc.) refer to Section D 4, Maintenance operations.

Removal of the front brake system


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

Loosen the bolts (16) securing support (15) and withdraw hose (8) from the support.

Remove the hose guides (12) from the hoses.

Unscrew the banjo bolts (6) on both brake calipers and disconnect the calipers from the hoses (8), recovering the sealing washers (4).

Free the hose (8) from the guide (A) on the mudguard.

Unscrew the two bolts (2) securing the right-hand front caliper (3) to the fork leg.

Repeat the operation for the left-hand caliper (10).

Removal of the brake discs


Operation	Section reference
Remove the front wheel	G 1, Removal of the front wheel

The front discs are comprised of a rotor.

Undo the bolts (14) securing the brake discs to the wheel and remove the discs (13) from both sides of the wheel.

Refitting the brake discs

Before refitting the brake disc to the wheel, clean all contact surfaces thoroughly and apply threadlocker to the threads of retaining bolts (14).

Screw in the bolts (14) securing the front brake disc (13) to the front wheel in the sequence: 1-3-5-2-4-6.

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


Operation	Section reference
Refit the front wheel	G 1, Refitting the front wheel

Overhauling the front brake components

Important

Critical safety components. The brake caliper manufacturer advises against any servicing of the internal components of calipers. Incorrect overhaul of this component could endanger rider safety.

Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly.

Refer to the exploded view at the beginning of this section for indications on renewal of the above components.

The brake disc must be clean without any signs of rust, oil, grease or dirt and no deep scoring.

To check brake disc wear, refer to the service limits given in the paragraph “Hydraulic brakes”(Sect. C 1.1).

Refitting the front brake system

Warning

When refitting the brake system, take care to position correctly the end fittings of the hose (8) connecting the master cylinder and calipers (3) and (10).

Warning

If incorrectly positioned, the hose can affect brake operation and foul moving parts.

Fit the sealing washers (4) to either side of the connection fitting when connecting the brake hose to the brake caliper.

Reconnect the hose (8) to the front brake calipers (10) and (3) and tighten the bolts (6) to their specified torque (Sect. C 3, Frame torque settings).

Fit the calipers (3) and (10) over the disc.

Grease the threads and undersides of the heads of the bolts (2).

Fit the two bolts (2) securing the caliper to the fork leg.

Tighten the bolts (2) to the specified torque (Sect. C 3, Frame torque settings).

Locate the brake master cylinder-lever assembly (Sect. F 3, Refitting the front brake master cylinder).

If removed, insert the clips (12) in the front brake hose grommets (B), positioning them so that the tabs (C) lie flush with the tops of the grommets, without however altering their position relative to the brake hoses.

Notes

Apply the recommended lubricant to facilitate insertion of the clips.

Position the grommets so they seat against the sleeves (D), orienting the clips so that they are positioned on the front sides of the hoses, as shown in the figure.

Notes

The purpose of the sleeves (D) and (C) is to provide positioning reference points for the brake hose guides; it is therefore important not to alter their positions on the brake hoses.

Insert the hose (8) in the headlight support (15), making sure that the guide (12) is positioned correctly.

The special shape of the guide restrains the movement of hose (8) during braking.

Position the hose as shown in the figure.

Tighten the bolts (16) to the specified torque (Sect. C 3, Frame torque settings).


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