Checking brake pad wear and replacing front brake pads
Warning
Brake fluid is corrosive and will damage paint. Avoid contact with eyes and skin. In case of accidental contact, wash thoroughly with water.
Important
On handing over the motorcycle after changing the brake pads, inform the customer that the front brake must be used gently for the first 100 km to allow the pads to bed in completely.
Look through the slot in the calliper to make sure the groove in the brake pad friction material (1) is still visible.
Important
If either of the pads is worn, both pads must be renewed as a set.
Note
Work in the same way on both front brake callipers.
Loosen the two screws (1) and remove the calliper from the disc.
Remove the safety cotter pin (2).
Turn pin (3) counter-clockwise.
Recover spring (4).
Force the calliper pistons back into their seats by forcing the old brake pads apart.
Remove the worn pads (5).
Note
Change pads that have a shiny or “vitrified” appearance.
Fit the new pads and the relevant spring (4) as shown.
Fit pad retaining pin (3) and fix it with safety cotter pin (2).
Tighten retaining screws (1) to 25 Nm ±5%.
Turn the pad retaining pin (3) counter clockwise.
Operate the brake lever repeatedly so that the pads are firmly bedded in against the disc by the force of the brake fluid.
Check that through the sight glass (A) that the level in the master cylinder tank is not below the MIN mark.
If necessary, top up as follows.
Turn the handlebar so that the reservoir is levelled.
Remove cover (6) with membrane from the front brake fluid reservoir (7) by loosening screws (8).
Top-up with specified fluid until reaching the Max. mark.
Being the brake callipers a safety component of the engine, follow instructions indicated in Section "Removing the front brake system".