Section 09
BRAKES
Subsection 02
(HYDRAULIC BRAKES)
VMR2004_028_09_02A.FM
09-02-9
Measure thickness of the disc. Minimum thick-
ness is 3.5 mm (.13 in).
Replace disc if not within specifications.
CAUTION:
Brake discs should never be machined.
Turn the disc by hand and check run out.
Removal
Front Brake Disc
Remove caliper as described previously.
After removing the caliper, suspend it out of the
way.
CAUTION:
Do not let the caliper hang by the
hose and don’t stretch or twist the hose.
Wheel hub has to be removed from vehicle to re-
place brake disc Refer to FRONT DRIVE.
Remove screws
no. 39
retaining brake disc
no. 38
to wheel hub. Discard screws.
NOTE:
Heat up disc around screws to facilitate re-
moval.
Rear Brake Disc
Refer to REAR AXLE for brake hub removal instruc-
tions.
Installation
Install brake disc on hub and tighten in a criss-
cross sequence.
Install new self-locking screws
no. 39
and torque
them.
BRAKE LEVER
Removal and Installation
Use the same procedure than the front master
cylinder.
BRAKE PEDAL
Removal
Remove RH side foot protector.
Refer to BODY
for removal procedure.
Unhook the return spring
no. 40
.
1. Master cylinder
2. Return spring
3. Brake pedal
Remove circlip
no. 41
, washer
no. 42
and O-ring
no. 43
then remove pedal
no. 5
from pivot.
Remove the O-ring
no. 44
on the pivot.
NOTE:
Clean O-ring and pivot pin with BOMBARDIER
LUBE (P/N 293 600 016).
Installation
For installation, reverse the removal procedure.
Check O-rings for damage, change if necessary.
Apply synthetic grease (P/N 293 550 010).
DISC MINIMUM
THICKNESS
3.5 mm (.13 in)
MAXIMAL DISC RUN
OUT
0.5 mm (.02 in)
1
V02K0OA
4
2
3
V02K0DA
1
2
3
Summary of Contents for DS 650
Page 1: ......
Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
