User Guide

Chapter 6 Part B Brakes, wheels and tires (XV700-1100 models)
6B-9
Installation
15 Install the caliper, tightening the mounting bolts or nut to the
torque listed in this Chapter's Specifications.
16 Connect the brake hose to the caliper, using new sealing washers
on each side of the fitting. The neck of the hose union should fit
between the two cast lugs on the caliper body. Tighten the banjo fitting
bolt to the torque listed in this Chapter's Specifications.
17 Fill the master cylinder with the recommended brake fluid (see
Chapter 1) and bleed the system (see Section 8). Check for leaks.
18 Check the operation of the brakes carefully before riding the
motorcycle.
4 Brake disc - inspection, removal and installation
Inspection
Refer to illustration 4.3
1 Support the bike securely so it can't be knocked over during this
procedure.
2 Visually inspect the surface of the disc for score marks and other
damage. Light scratches are normal after use and won't affect brake
operation, but deep grooves and heavy score marks will reduce
braking efficiency and accelerate pad wear. If the disc is badly grooved
it must be machined or replaced.
3 To check disc runout, mount a dial indicator to the fork leg with
the plunger on the indicator touching the surface of the disc about 1/2-
inch from the outer edge (see illustration). Slowly turn the wheel and
watch the indicator needle, comparing your reading with the limit listed
in this Chapter's Specifications or stamped on the disc itself. If the
runout is greater than allowed, check the hub bearings for play (see
Chapter 1). If the bearings are worn, replace them and repeat this
check. If the disc runout is still excessive, it will have to be replaced.
4 The disc must not be machined or allowed to wear down to a
thickness less than the minimum allowable thickness, listed in this
Chapter's Specifications. The thickness of the disc can be checked
with a micrometer. If the thickness of the disc is less than the minimum
allowable, it must be replaced.
Removal
5 Remove the wheel (see Section 11 for front wheel removal or
Section 12 for rear wheel removal). Caution: Don't lay the wheel down
and allow it to rest on the disc - the disc could become warped. Set the
wheel on wood blocks so the disc doesn't support the weight of the
wheel.
6 Mark the relationship of the disc to the wheel, so it can be
installed in the same position. Bend back the lockwasher tabs (1981
through 1983 models) and remove the bolts that retain the disc to the
wheel (see illustration 2.3b, 2.5b, 2.7, 2.9b or 2.11). Loosen the bolts
a little at a time, in a criss-cross pattern, to avoid distorting the disc.
Once all the bolts are loose, take the disc off.
7 Take note of any paper shims that may be present where the disc
mates to the wheel. If there are any, mark their position and be sure to
include them when installing the disc.
Installation
8 Position the disc on the wheel, aligning the previously applied
matchmarks (if you're reinstalling the original disc). Make sure the
arrow (stamped on the disc) marking the direction of rotation is
pointing in the proper direction.
9 Apply a non-hardening thread locking compound to the threads
of the bolts. Install the bolts with (use new lockwashers on 1981
through 1983 models), tightening them a little at a time, in a criss-cross
pattern, until the torque listed in this Chapter's Specifications is
reached. Clean off all grease from the brake disc using acetone or
brake system cleaner.
10 Install the wheel.
11 Operate the brake lever several times to bring the pads into
contact with the disc. Check the operation of the brakes carefully
before riding the motorcycle.
5.3a Master cylinder (1981 through 1983 XV750, XV920K and
XV920MK models) - exploded view
1 Master cylinder body 8 Lockwashers
2 Piston assembly • 9 Ring (XV750 only)
3 Diaphragm 10 Brake hose
4 Reservoir cover ' 11 Rubber boot
5 Screws . 12 Union bolt
6 Handlebar clamp . 13 Sealing washers
7 Bolts 14 Hose guide
5 Front brake master cylinder - removal, overhaul and
installation
1 If the master cylinder is leaking fluid, or if the lever does not
produce a firm feel when the brake is applied, and bleeding the brakes
does not help, master cylinder overhaul is recommended. Before
disassembling the master cylinder, read through the entire procedure
and make sure that you have the correct rebuild kit. Also, you will need
some new, clean brake fluid of the recommended type, some clean
rags and internal snap-ring pliers. Note: To prevent damage to the
paint from spilled brake fluid, always cover the fuel tank when working
on the master cylinder.
2 Caution: Disassembly, overhaul and reassembly of the brake
master cylinder must be done in a spotlessly clean work area to avoid
contamination and possible failure of the brake hydraulic system
components.
Removal
Refer to illustrations 5.3a, 5.3b and 5.3c
3 Loosen but do not remove the screws holding the reservoir cover
in place (see the accompanying illustrations, illustration 2.9b or
illustration 2.11).