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Table 3-11: Maintenance of Front and Rear Brakes
3. Refer to Table 3-11 in respect of damage forms, fault phenomena and common
maintenance methods of front and rear wheels:
Component
Name
Damage Form
Component Fault
Phenomenon
Motorcycle Fault
Phenomenon
Maintenance Method
Brake pads
Friction plates are
worn.
Brake is out of control
or brake pads cannot
return.
Replace brake pads
as a set.
The end of brake
pad is worn to a
slot.
R e a r b r a k e m a k e s
abnormal sound or is
out of control.
The area of brake
shoe touching with
brake drum is too
small.
Brake is out of control .
Re p a i r o r r e p l a c e
f r i c t i o n p l a t e s o f
brake pads
T h e e l a s t i c i t y o f
brake shoe spring
is not enough or
broken.
B r a k e p a d s c a n n o t
return.
R e p l a c e r e t u r n
spring.
Brake cam
Moving par ts are
rusty or have foreign
things.
The rotation of brake
cam is not flexible.
Brake is out of control
or cannot return.
Clean and lubricate
brake cam.
The circle surface of
brake cam is worn.
Brake is out of control . Replace brake cam.
Trouble 3: after several attempts to apply the brake, it feels like braking is soft or gone.
Cause study: 1. Poor sealing of brake fluid which leads to leakage of brake fluid; 2. Brake system
vacuum filling fails. It fails to fill brake fluid with the 2nd circuit of ABS control module; 3. Brake caliper
falls off.
Methodology: 1. Check the brake lines for leakage of brake fluid and fasten the leaking points and bleed
air again.2. After bleeding, attempts are made to drive. Ensure bleeds occur again when ABS is operating
until it feels comfortable with braking (mainly for the purpose of filling the 2nd circuit of ABS control
module with brake fluid); 3. Fasten the brake caliper again.
Trouble 4: as brake is applied, the wheel is locked and can not released. There is no reacting force from
ABS.
2. The torque required for the connecting bolt for the braking system:
M u s h r o o m h e a d
connecting bolt,
required torque:
20N.m
±
2N.m
C o o p e r p a c k i n g
c o n n e c t i n g b o l t,
r e q u i r e d t o r q u e:
30N.m
±
2N.m
3. The requirements on brake fluid: DOT 4 or higher can be used only.
Cause study: misled connection of brake line
Methodology: reconnect the brake line in a
correct sequence which is shown in the figure
below:
Interface definition
FM front wheel master cylinder
FM front wheel wheel cylinder
RM rear wheel master cylinder
RM rear wheel wheel cylinder
