Rear brake control

4 -	Rear brake control

1	Rear brake cylinder

2

3	Master cylinder-reservoir line

4	Oil reservoir

5	Filler plug

6

7	Special screw

8

9

10	Clevis pin

11

12

13	Rear brake hose

14	Brake pedal

15	Rubber protection

16

17

18

19

20

21

22	Pedal rotation pivot

23

24	Spare connector

25

26

27	Adjusting screw

28

Parts catalogue


1100	Rear brake
1100S	Rear brake

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the rear brake master cylinder

Critical safety components. The brake master cylinder manufacturer recommends that you do not attempt to service the internal components of the brake master cylinder. Incorrect overhaul of these critical safety components can endanger rider safety.

Maintenance operations on master cylinder are limited to replacing: control lever, reservoir unit and its fasteners and complete master cylinder body.


Operations	Reference - See Section
Drain the brake circuit	D 4, Draining the brake circuits
Remove the rear right-hand footpeg plate	H 4, Removing the footpegs

Unscrew the special screw (7) securing the rear brake hose and collect the washers (6).

Undo and remove the screws (12) fixing the master cylinder (1).

In this way master cylinder (1) is released from footpeg plate.

Remove clip (11) from footpeg plate (A) sliding it off the clevis pin (10), then loosen nut (9) and rod (8).

Unscrew the retaining screw (23) of the oil reservoir (4).

Remove the complete master cylinder and reservoir (4) with line (3).

Remove the footpeg plate, as described in Sect. H 4, Removing the footpegs.

Unscrew the screw (16) securing the pedal (14) to pivot (22).

Remove pedal (14) and then remove washer (17) and O-ring (18).

Release spring (21) from pivot (22) and remove pivot from right footpeg plate.

Remove spring (21) from its seat and then remove washer (20) and O-ring (18).

If the bush (19) inside the footpeg plate needs replacing, drive the replacement bush in place using a press. The bush must be seated 2 mm deep below the footpeg plate (A) outer face.

Refitting the rear brake master cylinder

Reassembling the rotation pivot

After servicing the rear brake control, check the brake pedal position following the instructions given in Sect. D 4, Adjusting the position of the gear change and rear brake pedals.

Fit washer (20) onto pivot (22).

Smear specified grease on pivot and O-ring (18).

Fit the O-ring on pivot, push fully home against washer (20).

Smear specified grease on the O-ring seat (18).

Install the spring (21) and rotation pivot (22) on footpeg plate, push pivot fully home and set spring (21) as shown.

Refitting the rear brake footpeg

During the following procedure it is of utmost importance to keep pivot fully home (22) against footpeg plate.

Smear specified grease on the O-ring (18) and on its seat.

Fit the O-ring (18) and washer (17) onto pivot (22).

Install the rear brake lever (14) and take it fully home against washer.

Position the brake lever so that clamp cut-off aligns with pivot notch (A).

Start screw (16) on brake lever, then tighten it to the specified torque (Sect. C 3, Frame torque settings).

Refit the right footpeg plate, as described in Sect. H 4, Refitting the footpegs.

Refitting the rear brake master cylinder

Set the rear brake master cylinder (1) to the vehicle and install the retaining screws (12); apply recommended threadlocker.

Tighten the screws (12) to the specified torque (Sect. C 3, Frame torque settings).

Position the reservoir (4) into its plate on frame and secure it with the screw (23). Tighten the screw to the specified torque (Sect. C 3, Frame torque settings).

Refit line (13) setting seals (6) in either side of the fitting and secure it using special screw (7).

Position brake line fitting (13) 90° inward with respect to master cylinder axis.

Tighten the special screws (7) to the specified torque (Sect. C 3, Frame torque settings).

If the assembly of rod (8), clip (11) and clevis pin (10) was separated, reassemble by tightening nut (9) onto rod (8), then screw rod onto clevis pin (10) until obtaining the size indicated in the figure.

Tighten the rod and tighten the nut (9) to the specified torque (Sect. C 3, Frame torque settings) onto clevis pin (10).

Install the complete rear brake control rod onto rotation pivot (22) and lock it in place using the relevant spring (11).

Now fit the other end of rod (8) inside the master cylinder (1), after lubricating with the recommended grease.

Rear brake hose routing