Honda TRANSALP XL600-650V (1987-2002) [198/291] Brakes wheels and tyres 7 13
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Honda TRANSALP XL600-650V (1987-2002) [198/291] Brakes wheels and tyres 7 13

Honda TRANSALP XL600-650V (1987-2002) [198/291] Brakes wheels and tyres 7 13

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Brakes wheels and tyres 7 13 II the air pressure Is too high and the piston i forced out the caliper and or piston 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 Caution Do not try to remove the piston by levering it out or by using pliers or any other grips 7 Using a wooden or plastic tool remove the dust seal from the caliper bore Discard it as a new one must be used on installation If a metal tool is being used take great care not to damage the caliper bore 8 Remove and discard the piston seal In the same way 9 Clean the piston and bore 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 10 Inspect the caliper bore and piston for signs of corrosion nicks and burrs and loss of plating If surface defects are present the caliper and or piston must be replaced with new ones If the necessary measuring equip ment is available compare the dimensions of the piston and bore to those given in the Specifications Section of this Chapter replacing any component that is worn beyond its service limit It the caliper is in bad shape the master cylinder should also be checked 11 Remove the collar from the rear slider pin rubber boot and remove the boots from the caliper and the bracket see illustrations Clean off all traces of corrosion and hardened grease from the collar boots and pins Renew the rubber boots if they are damaged deformed or deteriorated Apply a smear of silicone based grease to the collar boots and slider pins Fit the boots into their bores then lit the collar Into the rear boot see illustrations 5 11b and a 12 Lubricate the new piston seal with clean brake fluid and fit H in its groove in the caliper bore 13 Lubricate the new dust seal with clean brake fluid and fit it in its groove in the caliper bore 14 Lubricate the piston with clean brake fluid and fit it closed end first into the caliper bore Using your thumbs push the piston all the way in making sure it enters the bore squarely A 5 5 Rear brake caliper assembly 1 Piston 2 Dust seal 3 Piston seal 4 Bleed valve 5 Caliper 6 Pad spring and hardened grease from the collar boots and pins Renew the rubber boots if they are damaged deformed or deteriorated Apply a smear of silicone based grease to the collar boots and slider pins Fit the boots into their bores then fit the collar into the rear boot see illustrations 5 11b and a 16 Make sure that the pad spring and pad guide are correctly fitted see illustrations 5 4a and b Slide the caliper into the bracket see illustration 5 2 17 If removed install the brake pads see Section 2 If the pads are already installed pivot the caliper down onto the disc while keeping the pads held in position locating the leading edges correctly against the guide on the bracket see illustration 2 35b Apply a suitable non permanent thread locking compound to the rear mounting bolt slider pin and tighten it securely see illustration 2 35c 18 If detached connect the brake hose to the caliper using new sealing washers on each side of the fitting Align the hose as noted on removal see illustration 5 1a or b 7 Boot 8 Mounting bolt slider pin 9 Collar 10 Slider pin Tighten the banjo bolt to the torque setting specified at the beginning of the Chapter 19 Fill the master cylinder reservoir with DOT 4 brake fluid see Daily pre ride checks and bleed the hydraulic system as described in Section 10 20 Check for leaks and thoroughly test the operation of the brake before riding the motorcycle 6 Rear brake plate assembly removal overhaul and installation drum brake Note This procedure applies only to XL600VH to L 1987 to 1990 models Warning The dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not under any A Installation 15 If the caliper has not been overhauled remove the collar from the rear slider pin rubber boot and remove the boots from the caliper and the bracket see illustrations 6 11a and b Clean off all traces of corrosion 5 11a Withdraw the collar A and remove the caliper boot B 5 11b and the bracket boot

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