16. BRAKE SYSTEM 16-0 BRAKE SYSTEM UXV 500
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- Victor Ramsey
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1 16 BRAKE SYSTEM 16 SERVICE INFORMATION TROUBLESHOOTING BRAKE PADS REPLACEMENT FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION FRONT BRAKE FLUID CHANGE/AIR BLEED REAR BRAKE FLUID CHANG/AIR BLEED REAR BRAKE/PARKING BRAKE CALIPER REMOVAL/ INSPECTION/INSTALLATION BRAKE MASTER CYLINDERS REMOVAL / INSTALLATION BRAKE PADEL BRAKE ASSY PARKING REAR BRAKE DISK
2 SERVICE INFORMATION GENERAL INSTRUCTIONS During servicing, keep oil or grease off the brake pads and brake disk. Drain the brake fluid from the hydraulic brake system before disassembly. Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads. Do not use brake fluid for cleaning. Bleed air from the brake system if the brake system is removed or the brake is soft. Do not allow any foreign matters entering the brake reservoir when filling the brake reservoir with brake fluid. Brake fluid will damage painted, coated surfaces and plastic parts. When working with brake fluid, use shop towels to cover and protect painted, rubber and plastic parts. Wipe off any splash of brake fluid with a clean towel. Do not wipe the machine with a towel contaminated by brake fluid. Make sure to use recommended brake fluid. Use of other unspecified brake fluids may cause brake failure. Inspect the brake operation before riding. SPECIFICATIONS Unit: mm (in) Item Standard Service Limit Brake disk thickness FR:4.0(0.156) RR:5.0(0.195) FR:3 (0.12)RR:4(0.156) Brake disk runout 0.3 (0.012) TORQUE VALUES Caliper mounting bolt Brake pad mounting bolt Brake disc bolt Bleed valve nut Brake hose bolt Master cylinder mounting bolt Delay valve mounting bolt Delay valve plug 2.7 kgf-m (27 N-m, 19.5 lbf-ft) 1.8 kgf-m (18 N-m, 13 lbf-ft) 3.5 kgf-m (35 N-m, 25.2 lbf-ft) 0.6 kgf-m (6 N-m, 4.32 lbf-ft) 3.5 kgf-m (35 N-m, 25 lbf-ft) 1.2 kgf-m (12 N-m, 8.6 lbf-ft) 1.2 kgf-m (12 N-m, 8.6 lbf-ft) 5 kgf-m (50 N-m, 36 lbf-ft) 16-1
3 TROUBLESHOOTING Loose brake lever Air in hydraulic brake system Brake fluid level too low Hydraulic brake system leakage Poor brake performance Air in brake system Deteriorated brake fluid Contaminated brake pads and brake disk Worn brake pads Worn brake master cylinder piston oil seal Clogged brake fluid line Deformed brake disk Unevenly worn brake caliper Tight brake Pedal Seized piston Clogged hydraulic brake system Smooth or worn brake pad Brake noise Contaminated brake pad surface Excessive brake disk run out Incorrectly installed caliper Brake disk or wheel not aligned Hard braking Seized hydraulic brake system Seized piston 16-2
4 BRAKE PADS REPLACEMENT FRONT BRAKE PADS Remove the front wheel. (refer to the FRONT WHEEL REMOVAL/INSPECTION/ INSTALLATION section in the chapter 14). Remove the two brake pad pins from the brake caliper. Remove the two mounting bolts from brake caliper and then remove brake caliper. Do not operate the brake lever during or after brake pad removal. Replace the brake pads as a set, otherwise braking performance will be adversely affected. Compress the brake caliper holder and remove brake pads. 16-3
5 A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins. Install the brake caliper mounting bolts to the specified torque. Torque: 2.7 kgf-m (27 Nm, 19.5 lbf-ft) Tighten the brake pad mounting pins. Torque: 1.8 kgf-m (18 Nm, 13 lbf-ft) REAR BRAKE PADS Remove the rear wheel. (refer to the REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION section in the chapter 15). 16-4
6 REAR BRAKE PADS Rear brake Remove the rear wheel. (refer to the REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION section in the chapter 15). The replacement of rear brake and front brake pads are the same. Rear brake (combined) Remove the rear wheel. (refer to the REAR WHEEL REMOVAL/INSPECTION/ INSTALLATION section in the chapter 15). Remove the two brake pad pins from the brake caliper. Remove the two mounting bolts from brake caliper and then remove brake caliper. Do not operate the brake lever during or after brake pad removal. Replace the brake pads as a set, otherwise braking performance will be adversely affected. 16-5
7 Compress the brake caliper holder and remove brake pads. A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. Install the new brake pads. Install the brake pad mounting pins. 16-6
8 Install the brake caliper mounting bolts to the specified torque. Torque: 2.7 kgf-m (27Nm, 19.5 lbf-ft) Tighten the brake pad mounting pins. Torque: 1.8 kgf-m (18 Nm, 13 lbf-ft) 16-7
9 FRONT BRAKE DISCS REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the front wheel hub (refer to the FRONT WHEEL HUB REMOVAL/INSPECTION/ INSTALLATION section in the chapter 14). Remove the four bolts and then remove the brake disc. INSPECTION Measure the brake disc thickness. Service Limit: 3 mm (0.12 in) Measure the brake disk run out. Service Limit: 0.3 mm (0.012 in) INSTALLATION Brake Disc Install the brake disc onto the wheel hub. Install and tighten the new four bolts to the specified torque. Torque: 3.5 kgf-m (35 Nm, 25.2 lbf-ft) 16-8
10 REAR BRAKE DISC REMOVAL/INSPECTION/ INSTALLATION REMOVAL Remove the rear wheel hub Remove the rear wheels. Remove the rear drive bolts. Disconnect the rear drive and shaft Rear propeller connect position(holder disk rear brake). Remove the rear drive Remove the 5 bolts and then remove the brake disc.(use the impact driver remove it) INSPECTION Measure the brake disc thickness. Brake Disc Service Limit: 4 mm (0.16 in) Measure the brake disk run out. Service Limit: 0.3 mm (0.012 in) INSTALLATION Install the brake disc onto the wheel hub. Install and tighten the new four bolts to the specified torque. Torque: 3.5 kgf-m (35 Nm, 25.2 lbf-ft) Impact Driver 16-9
11 Cap FRONT BRAKE FLUID CHANGE/AIR BLEED (OFF ROAD) BRAKE FLUID CHANGE Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Connect a transparent hose to the brake caliper bleed valve (right and calipers) and then loosen the bleed valve nuts. Use a syringe to draw the brake fluid out through the hose. Then, tighten the bleed valve nuts. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) Bleed Valve Nut Reservoir Fill the brake reservoir with brake fluid
12 Connect a transparent hose to the right caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose. Then, tighten the bleed valve nut. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) Connect a transparent hose to the left caliper bleed valve and then loosen the bleed valve nuts. Use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose. Then, tighten the bleed valve nut. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) When drawing brake fluid with the syringe, the brake fluid level should be kept over 1/2 of the brake reservoir height. Use only the recommended brake fluid. Recommended Brake Fluid: DOT
13 BRAKE SYSTEM BLEEDING 1. Connect a transparent hose to the bleed valves (right and left caliper). 2. Fully apply the brake pedal after continuously pull it several times. Then, loosen the right caliper bleed valve nut to bleed air from the brake system. 3. Fully apply the brake pedal after continuously to tread it several times. Then, loosen the left caliper bleed valve nut to bleed air from the brake system. 4. Repeat these steps until the brake system is free of air. When bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height. Bleed Valve 16-12
14 REAR BRAKE FLUID CHANGE/AIR BLEED BRAKE LEVER Brake fluid change Place the machine on the level ground and set the handlebar upright. Remove the two screws from the brake fluid reservoir cap. Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Cap Reservoir Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose. Then, tighten the bleed valve nut. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) When drawing brake fluid with the syringe, the brake fluid level should be kept over 1/2 of the brake reservoir height. Use only the recommended brake fluid. Recommended Brake Fluid: DOT-4 Bleed Valve 16-13
15 Brake system bleeding 1. Connect a transparent hose to the bleed valve. 2. Fully apply the brake pedal after continuously to tread it several times. Then, loosen the caliper bleed valve nut to bleed air from the brake system. 3. Repeat these steps until the brake system is free of air. When bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height. Bleed Valve BRAKE PEDAL Brake fluid change Place the machine on the level ground and set the handlebar upright. Remove the brake fluid reservoir cap. Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Cap Reservoir 16-14
16 Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the transparent hose. Then, tighten the bleed valve nut. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) When drawing brake fluid with the syringe, the brake fluid level should be kept over 1/2 of the brake reservoir height. Use only the recommended brake fluid. Recommended Brake Fluid: DOT-4 Bleed Valve Brake system bleeding 1. Connect a transparent hose to the bleed valve. 2. Fully apply the brake pedal after continuously depress it several times. Then, loosen the caliper bleed valve nut to bleed air from the brake system. 3. Repeat these steps until the brake system is free of air. When bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height. Bleed Valve 16-15
17 REAR BRAKE/PARKING BRAKE CALIPER REMOVAL/INSTALLATION (ON ROAD) Parking Brake Cable Drain the brake fluid from the hydraulic brake system (refer to the COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD) section in this chapter). Disconnect the parking brake cable from the caliper. Remove the brake fluid hose bolt and two washers from the caliper. Remove the brake pads (refer to the BRAKE PADS REPLACEMENT section in this chapter). Remove the brake caliper. INSTALLATION Install the brake fluid hose with the attaching bolt and two new sealing washers, then tighten the bolt to the specified torque. Torque: 3.5 kgf-m (35 Nm, 25 lbf-ft) Connect the parking brake cable. Fill the specified brake fluid and bleed air from the brake system (refer to the COMBINATION BRAKE FLUID CHANGE/AIR BLEED (ON ROAD) section in this chapter). Adjust the parking brake lever (refer to the PARKING BRAKE ADJUSTMENT section in the chapter 3)
18 BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY Remove the front or rear brake caliper (refer to the FRONT BRAKE CALIPERS REMOVAL/INSTALLATION section or REAR BRAKE CALIPERS REMOVAL/INSTALLATION section in this chapter). Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston
19 Push the piston dust seal inward to remove. Dust Seal Pushing the piston oil seal outward to remove it. Clean the seals groove with brake fluid. Be careful not to damage the piston surface. Inner Oil Seal Remove the caliper bracket. Caliper Bracket INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper. Inspect the dust boots for deterioration or damage. If any damages are found, replace them with a new ones
20 ASSEMBLY Wash the brake caliper components with new brake fluid before reassembly. Do not wipe the brake fluid off with a rag after washing the components. When washing the components, use the specified brake fluid (DOT 4). Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc. Apply brake fluid to all of the seals, brake caliper bore and piston before reassembly. Apply silicone grease to the caliper bracket pins
21 REAR BRAKE/PARKING BRAKE CALIPER DISASSEMBLY/INSPECTION/ ASSEMBLY DISASSEMBLY/INSPECTION Remove parking brake caliper (refer to the REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION (ON ROAD) section in this chapter). Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston. Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper
22 Inspect the dust boots for deterioration or damage. If any damages are found, replace them with a new ones. Dust Boot Remove the caliper bracket. Remove the dust boot. Caliper Bracket Remove the dust seal and piston seal. Dust Seal Piston Seal Loosen the lock nut while hold the adjusting bolt. Remove the adjusting bolt. Remove the parking brake arm and spring. Adjusting Bolt Parking Brake Arm Lock Nut Spring 16-21
23 Inspect the dust boot for deterioration or damage. If any damage is found, replace it with a new one. Remove the drive bolt and dust boot. Dust Boot Drive Bolt Inspect the drive shaft and shaft guide for wear or damage. Brake Shaft Shaft Guide Remove the two bolts and parking brake case. Parking Brake Case 16-22
24 Remove the O-ring. O-ring Inspect the O-ring for wear or damage. If any damages are found, replace it with a new one. O-ring INSTALLATION Apply silicone grease to the new O-ring, then install the new O-ring. O-ring 16-23
25 Install the parking brake case and two bolts. Tighten the bolts securely. Parking Brake Case Apply silicone grease to the new piston seal and new dust seal, then install them. Piston Seal/Dust Seal Install the piston. Piston Dust Boot Apply silicone grease to the brake shaft, then install it. Apply silicone grease to the dust boot, then install it. Brake Shaft 16-24
26 Press the piston and turn the brake shaft counterclockwise to expand boot, then the brake shaft does not touch piston. Dust Boot Piston Install the parking brake arm and spring. Align the parking brake arm with the brake fluid inlet hole as shown. Parking Brake Arm Spring Brake Fluid Inlet hole Install the adjusting bolt and lock nut. Do not turn in the adjusting too much and do not tighten the lock nut. Adjusting Bolt Lock Nut 16-25
27 Install the dust boots. Apply silicone grease to caliper bracket, then install it. Dust Boot Caliper Bracket Install the spring plate. Spring Plate Install the parking brake caliper (refer to the REAR BRAKE/PARKING BRAKE CALIPER EMOVAL/INSTALLATION (ON ROAD) section in this chapter). Adjust the parking brake (refer to the PARKING BRAKE ADJUSTMENT (ON ROAD) section in the chapter 3)
28 BRAKE MASTER CYLINDERS REMOVAL / INSTALLATION REMOVAL Front/rear master cylinder Remove the brake reservoir cap and drain the brake fluid from the hydraulic brake system Cap Reservoir Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts. Remove the bolt/nut and then remove the brake lever. Remove fluid hose bolt/two washers and then disconnect the fluid hose. When removing the brake fluid hose bolt, be sure to place towels under the hose and plug the hose end to avoid brake fluid leakage and contamination. Drain Brake Fluid Bolt Remove the two master cylinder holder bolts.and rear stop switch spring remove the master cylinder
29 Remove the rear stop switch spring and rin comp brake rod then remove the master cylinder. rear stop switch spring Installation is in the reverse order of removal. BRAKE PEDAL Remove the E -ring from the brake pedal Remove the rear stop switch spring and rin comp brake rod then remove the brake pedal
30 BRAKE ASSY PARKING Remove the 2 bolts from the brake assy parking Remove the brake Parking switch connector and brake parking wire nuts then remove brake parking wire. Remove the brake assy parking switch Connector Connector 16-29
31 REAR BRAKE DISK REMOVAL Remove the two bolts attaching the skid plate. Remove the skid plate. skid plate Drain out the rear gear box oil as picture Remove the three bolts attaching the muffler. Remove the muffler. bolts 16-30
32 Remove the four nuts attaching the rear wheels. Remove the rear wheels. Remove the cotter pin. Remove the hub nut. Remove the rear wheel hub. Nut Cotter Pin Hub Nut Cotter Pin Hub 16-31
33 Remove the bolts/nut. Remove the knuckle attaching the upper arm as picture. Bolt/nut Remove the CVJ ASSY attaching the rear gear box assembly. knuckle CVJ ASSY Rear Gear Box 16-32
34 Remove the two bolts attaching the rear gear box. Remove the caliper from rear gear box. Caliper Remove the boot attaching the transmission out shaft
35 Remove two rear gear box mounting bolts/nuts from frame, pull the rear gear box back and rotate 90 then separate the rear gear box from transmission output shaft. Remove the rear gear box assembly. Remove the rear brake disk.. Remove the five bolts attaching the rear brake disk. Brake Disc INSTALLATION Installation is in the reverse order of removal. Impact Driver 16-34
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18_25~~ VI ~.' ""'~. ~~ ft lb), f? 8-13 N m qj ~O..f9 ( kg-m. .0 ~J. I i~" C;Q () 0 ~,t) ~ ft lb), ~, ' ~.
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