Brake Hose and Line Inspection
1. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting.
2. Check the brake lines for damage, rusting, and leaks. Also check for bent brake lines.
3. Check for leaks at hose and line joints and connections, and retighten if necessary.
4. Check the master cylinder and the VSA modulator-control unit for damage and leaks.
Brake Hose Replacement
NOTE:
Removal-Front
1. Remove the front wheel.
2. Disconnect the brake line (A) from the brake hose (B), then remove the brake hose clip (C).
3. Remove the banjo bolt (A), and disconnect the brake hose (B) from the caliper.
4. Remove the brake hose mounting bolt (C). then remove the brake hose.
Installation-Front
1. Install the brake hose (A) with the mounting bolt (B).
2. Connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D).
3. Install a new brake hose clip (A) to the brake hose (B) on the bracket, then connect the brake line (C).
Do not twist the brake hose.
4. After installing the brake hose, bleed the brake system.
5. Do these checks:
6. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheel.
Removal-Rear
1. Remove the rear wheel.
2. Disconnect the brake line (A) from the brake hose (B), then remove the brake hose clip (C).
3. Remove the banjo bolt (A), and disconnect the brake hose (B) from the caliper.
4. Remove the brake hose mounting bolt (C), then remove the brake hose.
Installation-Rear
1. Install the brake hose (A) with the mounting bolt (B).
2. Connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D).
3. Install a new brake hose clip (A) to the brake hose (B) on the bracket, then connect the brake line (C).
Do not twist the brake hose.
4. After installing the brake hose, bleed the brake system.
5. Do these checks:
6. Clean the mating surface of the brake disc/drum and the inside of the wheel, then install the rear wheel.
Parking Brake Cable Replacement
Exploded View
NOTE:
This will lead to stiff operation and premature cable failure.
1. Loosen the parking brake cable adjusting nut.
2. Remove the parking brake shoes, and disconnect the parking brake cable from the parking brake lever.
3. Remove the parking brake cable mounting bolts from the backing plate (A), and remove the parking brake cable (B).
4. Pull the parking brake cable, and remove it from the backing plate.
5. Reinstall the parking brake cable in the reverse order of removal, and note these items:
Apply the parking brake firmly 10 times then adjust it again.