Honda TRANSALP XL600-650V (1987-2002) [196/291] Brakes wheels and tyres 7 11
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Honda TRANSALP XL600-650V (1987-2002) [196/291] Brakes wheels and tyres 7 11

Honda TRANSALP XL600-650V (1987-2002) [196/291] Brakes wheels and tyres 7 11

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Brakes wheels and tyres 7 11 the hose noting the alignment with the caliper see illustration Plug the hose end or wrap a plastic bag tightly around to minimise fluid loss and prevent dirt entering the system Discard the sealing washers as new ones must be used on installation Note If you are planning to overhaul the caliper and don t have a source of compressed air to blow out the piston just loosen the banjo bolt at this stage and retighten it lightly The bike s hydraulic system can then be used to force the piston out of the body once the pads have been removed Disconnect the hose once the piston have been sufficiently displaced 2 On XRV models remove the fork guards see Chapter 8 On all models unscrew the bolt securing the brake hose in the clamp on the front fork and release it noting how it fits see illustration 2 3 3 If the caliper is being overhauled remove the brake pads see Section 2 On XL600V H to P 1987 to 1993 models and XRV750 L to N 1990 to 1992 models this involves removing the calipers so ignore Step 4 4 Unscrew the caliper bracket mounting bolts and slide the caliper assembly off the disc see illustration Overhaul Refer to illustrations 2 4a 2 4b and 2 18d for exploded views of the caliper 5 Separate the caliper from the bracket by sliding them apart see illustration If required remove the pad spring from the caliper and the guide from the bracket noting how they fit see illustrations 6 Clean the exterior of the caliper with denatured alcohol or brake system cleaner 7 Remove the pistons from the caliper body either by pumping them out by operating the brake pedal or by using compressed air If the compressed air method is used place a wad of rag over the pistons to act as a cushion then use compressed air directed Into the fluid inlet to force the pistons out of Ilie body Use only low pressure to ease the pistons out and make sure they are displaced at the same time If the air pressure is too high and a pistons are forced out the caliper and or pistons may be damaged Warning Never place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air as serious injury could result Place the caliper piston side down on a bench with the rag between them and let the air lift the caliper off the piston A Caution Do not try to remove the pistons by levering them out or by using pliers or any other grips 8 Using a wooden or plastic tool remove the dust seals from the caliper bore Discard them as new ones must be used on installation If a metal tool is being used take great care not to damage the caliper bores 9 Remove and discard the piston seals in the same way 4 1 Brake hose banjo bolt arrowed 10 Clean the pistons and bores with denatured alcohol clean brake fluid or brake system cleaner If compressed air is available use it to dry the parts thoroughly make sure it s filtered and unlubricated Caution Do not under any circumstances use a petroleum based solvent to clean brake parts 11 Inspect the caliper bores and pistons for signs of corrosion nicks and burrs and loss of plating If surface defects are present the caliper and or pistons must be replaced with new ones If the necessary measuring equip ment Is available compare the dimensions of the pistons and bores to those given in the Specifications Section of this Chapter replacing any component that is worn beyond its service limit If the caliper is in bad shape the master cylinder should also be checked 12 Remove the slider pin rubber boots from the caliper and the bracket see illustration Clean off all traces of corrosion and hardened 4 5a Separate the caliper and bracket 4 5c and the pad guide arrowed late model XL600V shown 4 4 Unscrew the bolts arrowed and slide the caliper off the disc grease from the boots and pins Renew the rubber boots if they are damaged deformed or deteriorated Apply a smear of silicone based grease to the boots and slider pins Fit the boots into their bores 13 Lubricate the new piston seals with clean brake fluid and fit them in their grooves in the caliper bores Note that on XL650V models different sizes of bore and piston are used see Specifications and care must therefore be taken to ensure that the correct size seals are fitted to the correct bores The same applies when fitting the new dust seals and pistons 14 Lubricate the new dust seals with clean brake fluid and fit them in their grooves in the caliper bore 15 Lubricate the pistons with clean brake fluid and fit them closed end first into the caliper bores Using your thumbs push the pistons all the way in making sure they enter the bore squarely 4 5b and remove the pad spring arrowed 4 12 Remove the rubber boots arrowed

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