4 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
 Spare parts catalogue
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 replacing the following parts: control lever, reservoir unit, reservoir fasteners and master cylinder fasteners.
 
Note
For the ABS rear braking system, also refer to Sect. G 9.1, ABS system operating information, Sect. G 9.2, System components, Sect. G 9.3, ABS components maintenance.
 
Undo the screw (21) and remove the reservoir (23) complete with the hose (16).
Unscrew the upper screw (A) securing the RH bracket to the swingarm.
Remove the washer between the bracket and the frame.
Unscrew the lower retaining screws (B) from crankcase.
Unscrew the screws (18) securing the rear brake master cylinder (17) to the footrest bracket (D).
Unscrew the banjo bolt (1) from the master cylinder (17), recovering the two sealing washers (2).
Remove the clamp (C).
Unscrew the pin (5) securing the rear brake pedal lever to the footrest bracket and remove the spring (6), the complete pedal lever (9) and the O-ring (24).
 
Disassembly of the rear brake control
The brake master cylinder is supplied only as a complete unit; internal components cannot be replaced.
To disassemble master cylinder external components, follow the indications given in the exploded view at the beginning of this section.
If the brake pedal (9) inner bushing (14) needs to be renewed, fit the new bushing using a suitable press and position it so that it is set in 2 mm from the outer face of the pedal.
To disassemble the various parts of the system, refer to the exploded view at the beginning of this chapter.
Warning
After performing an operation on the rear brake control, check the brake pedal position following the instructions detailed in Sect. D 4, Adjusting the position of the gear change and rear brake pedals.
Refitting the rear brake master cylinder
Lubricate the O-ring (24) and install it on the pin (5).
Lubricate also the other O-ring (24).
Fit the spring (6) and the rotation pivot pin (5) to the footrest bracket, pushing the pivot pin fully home and positioning the spring (6) as shown in the figure.
Apply threadlocker to the threads of the pivot pin (5).
Locate the line connecting rear brake master cylinder and ABS control unit (3) and washers (2) on the rear brake master cylinder (17) and fix it with the special screw (1).
Position the rear brake master cylinder (17) onto the footrest bracket (D) then start screws (18) in their thread.
Tighten the screws (18) to the specified torque (Sect. C 3, Frame torque settings).
Note
If the hose connecting the rear master cylinder to the ABS control unit (3) or the one connecting master cylinder and reservoir (16) are changed, ensure that the hose end fittings on master cylinder are positioned correctly.
 
Orientate the hoses (3) and (16) as illustrated in the figure and then tighten the screw (1) to the specified torque (Sect. C 3, Frame torque settings).
If the pushrod (19), clip (11) and fork (15) assembly has been dismantled, reassemble by screwing the nut (25) onto the pushrod (19) and then screw the pushrod into the clevis (15) to obtain the measurement indicated in the figure.
Restrain the pushrod and tighten the nut (25) against fork (15) to the specified torque (Sect. C 3, Frame torque settings).
Fit the rear brake control rod on the pivot bolt (9), securing it with the clip (11).
Now lubricate the other end of the pushrod (19) with the recommended grease and insert it in the master cylinder (1).
Refit the clamp (C).
Set the washer in-between the RH footrest bracket and the frame.
Fasten the right-hand side footrest bracket to the swinging arm using the screw (A), duly lubricated, and to engine using screws (B). Tighten the screws (A) and (B) to the specified tightening torque (Sect. C 3, Frame torque settings), following the indicated sequence.
 
Positioning of rear brake hose