3 - | Hydraulic front brake

1 | Pad retaining pin and clip

2 | Screw

3 | Right brake caliper

4 | Sealing washer, thickness 1

5 | Bleed valve

6 | Banjo bolt

7 | Dust cap

8 | Calipers–master cylinder hose

9 | Pair of brake pads

10 | Left brake caliper

11 | Springs

12 | Bracket

13 | Brake disc

14 | Screw

15 | Front brake hose

16 | Screw

17 | Banjo bolt

18 | Screw

19 | Washer

20 | Ring

21 | Rubber

22 | Clip

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 Sect. D 4, Draining the brake circuit.
Removal of the front brake system

Operation | Section reference
Draining the braking circuit | D 4, Draining the brake circuit

Unscrew the banjo bolt (6) securing the brake hose to the master cylinder and recover the sealing washers (4); remove the hose (8) from the master cylinder.
Release hose (15) from the retaining clips (22) and hose (8) from the bracket (12).
Remove the brake master cylinder (Sect. F 3, Removal of the front brake master cylinder).
Unscrew the two retaining screws (2) securing the left front brake caliper (10) to the fork leg.
Repeat the operation for the right brake caliper (3).
Unscrew the banjo bolts (17) from both calipers and recover the sealing washers (4).
Detach the front brake calipers from the hoses (8) and (15).
Removal of the brake discs
The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor. Both parts must be changed together as a pair.
Remove the front wheel (Sect. G 1, Removal of the front wheel).
Unscrew the six screws (14) securing the brake disc to the wheel and remove the disc (13).
Overhauling the front brake components
Important
Critical safety components. The manufacturer of the brake caliper advises against servicing 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 bleeder 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
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 screws (14).
Screw the six retaining screws (14) of front brake disc (13) into the front wheel in this sequence: 1-3-5-2-4-6.
Tighten the screws to the specified torque (Sect. C 3, Frame torque settings).
Refit the wheel to the motorcycle (Sect. G 1, Refitting the front wheel).
When refitting the brake system, take care to position correctly the end fittings on the hose (8) connecting the master cylinder and caliper.
Warning
If incorrectly positioned, the hose can affect brake operation and foul moving parts. Position the hose as shown in the figure.
When reconnecting the brake hose to the caliper or master cylinder, make sure to install the sealing washers (4) either side of the hose end fitting.
After positioning the fitting correctly, tighten the banjo bolt (6) to the specified torque (Sect. C 3, Frame torque settings).
Reconnect the hoses (8) and (15) to the front brake calipers (3) and (101) and tighten the bolts (17) to their specified torque (Sect. C 3, Frame torque settings).
Notes
Make sure that internal hose fitting (8) and external hose fitting (15) are installed to the RH brake caliper (10).
Fit the RH caliper (10) over the disc.
Apply the recommended grease to the screws (2).
Fit the screws (2) and hand tighten to fix the calipers to the fork legs then pre-tighten to the specified torque (Sect. C 3, Frame torque settings).
Repeat the operation for the LH brake caliper (3).
Operate the front brake lever two or three times until the circuit is pressurized and force the
pads against the brake disc.
Hold the lever pulled in towards the grip and tighten the caliper screwts (2) to the specified torque (Sect. C 3, Frame torque settings).
Insert the front brake hose (15) in the retaining clip (22) located on the front mudguard and hose (8) in the bracket (12).

Operation | Section reference
Filling the braking system | D 4, Filling the brake system with fluid