'61HN252' by American Honda Motor Co. - Page 321 of 540
http://services.honda.com/ServiceManual/SVC_MNL/61HN253/61HN2...
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3/9/2008 11:09 PM
[2005-2008] [TRX500 FA/FGA]
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake lining or pad dust, regardless of material composition could be hazardous to your health.
· Avoid breathing dust particles.
· Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first.
· A contaminated brake lining, drum, disc or pad reduces stopping power. Discard contaminated linings or pads, and
clean a contaminated drum or disc with a high quality brake digreasing agent.
· Check the brake system by applying the brake lever after the air bleeding.
· Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
· Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
· Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid as they may not be compatible.
· Always check brake operation before riding the vehicle.
SPECIFICATIONS
Unit: mm (in)
ITEM
STANDARD
SERVICE LIMIT
Front brake
Recommended brake fluid
DOT 4 brake fluid
Master cylinder I.D.
14.000 14.043 (0.5512 0.5529)
14.055 (0.5533)
Master cylinder piston O.D.
13.957 13.984 (0.5495 0.5506)
13.945 (0.5490)
Caliper cylinder I.D.
33.96 34.01 (1.337 1.339)
34.020 (1.340)
Caliper cylinder piston O.D.
33.878 33.928 (1.3338 1.3357)
33.870 (1.333)
Brake disc thickness
3.8 4.2 (0.15 0.17)
3.0 (0.12)
Brake disc runout
0.30 (0.012)
Rear brake
Drum I.D.
180.0 - 180.2 (7.086 7.095)
181 (7.1)
Lining thickness
5.3 5.32 (0.209 0.217)
To index mark
Rear brake lever free play
15 20 (9/16 13/16)
Rear brake pedal free play
15 20 (9/16 13/16)
TORQUE VALUES
Brake hose oil bolt
34 N·m (3.5 kgf·m, 25 lbf·ft)
Front master cylinder reservoir cap screw
2 N·m (0.2 kgf·m, 1.4 lbf·ft)
Front brake lever pivot bolt
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
Front brake lever pivot nut
5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
Front brake switch screw
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
Apply locking agent to the threads
Front master cylinder holder bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
Front brake caliper mounting bolt
44 N·m (4.5 kgf·m, 33 lbf·ft)
Front brake caliper slide pin bolt
23 N·m (2.3 kgf·m, 17 lbf·ft)
Splash guard
11 N·m (1.1 kgf·m, 8 lbf·ft)
Rear brake arm pinch bolt
20 N·m (2.0 kgf·m, 14 lbf·ft)
Rear wheel hub nut
137 N·m (14.0 kgf·m, 101 lbf·ft)
Castle nut
16-3
