6.1 - BRAKING SYSTEM
Both the front and rear brakes are the hydraulic oil disc type. As the brake pads wear out, the brake fluid level will drop. A leak in the system will also cause the level to drop. Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect the brake fluid level and the brake pads for wear. If the braking response of the front brake lever or rear pedal feels unusual, check the brake pads. If the brake pads are not worn beyond the recommended limits, there is probably air in the brake system. Refer to your local AJ1 dealer to have the air bled from the system.
Front Brake Lever
- Loosen the lock nut
- To position the brake lever away from the grip, turn the adjuster
- To position the brake lever closer to the grip, turn the adjuster counter-clockwise.
- Once you determine the lever is in a good position, while holding the adjuster, tighten the lock nut.
- Apply a little bit of silicone grease or marine grease to the contacting areas of the adjuster.
Rear Brake Pedal
- Loosen the lock nut and turn the push rod in the direction to raise the rear brake pedal or in the direction to lower it.
- Tighten the adjuster lock nut at the desired pedal height.
- The brake pedal height should be approximately level with the foot rest.
Front Fluid Level Check
- With the motorcycle in the upright position, check the brake fluid level. It should be above the indicator mark on the master cylinder. If the level is below the mark, check the brake pads for wear. Worn out pads should be replaced. If the brake pads are not worn out, check your brake system for leaks.
Rear Fluid Level Check
With the motorcycle in the upright position, check the brake fluid level. It should be above the indicator mark on the master cylinder. If the level is below the mark, check the brake pads for wear. Worn out pads should be replaced. If the brake pads are not worn out, check your brake
Hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders. Follow the procedures below to check and fill the cylinders with the specified brake fluid.
ADDING BRAKE FLUID (Front)
- Clean all dirt and dust from the master cylinder cap before opening.
- Remove the cap screws with a phillips head screwdriver.
- Remove the cap. Be careful not to damage the diaphragm gasket that is seated under the cap.
- Add the required amount in to the cylinder (DO NOT OVERFILL) Always use new fluid from a sealed container.
- Replace the diaphragm and cap and tighten the screws securely.
- Slowly squeeze the brake lever to be sure the brakes are working properly.
- Check the brake hose and brake caliper for leaks.
ADDING BRAKE FLUID (Front)
- Clean all dirt and dust from the master cylinder cap before opening.
- Remove the cap screws with a phillips head screwdriver.
- Remove the cap. Be careful not to damage the diaphragm gasket that is seated under the cap.
- Add the required amount in to the cylinder (DO NOT OVERFILL) Always use new fluid from a sealed container.
- Replace the diaphragm and cap and tighten the screws securely.
- Slowly squeeze the brake lever to be sure the brakes are working properly.
- Check the brake hose and brake caliper for leaks.
If you are unsure how to re-assemble a part, please contact your AJ1 dealer for servicing information and/or servicing.
Hydraulic disc brake systems use a brake caliper to squeeze the rotors (brake disc) which causes the motorcycle to stop. Inside the brake caliper are brake pads. The brake pads are the part of the brake system that makes contact, with the brake rotor. The pads must be checked in accordance with the maintenance schedule for the brake system as described on page 24. Follow the procedure below to check the brake pad wear. Brake pad wear depends on the severity of use and track conditions. (Usually, the pads will wear out faster with wet and dirty track conditions.)
ADDING BRAKE FLUID (Front)
- Inspect the brake pads at each maintenance interval through the wheel to determine the brake pad wear. (More frequently if you do a lot of riding).
- If either of the pads are worn down to a thickness of 1 mm, then both pads MUST be replaced.
- If one side has worn down more extensive than the other, consult your AJ1 dealer for a possible bad brake caliper.
- If you are unsure how to replace the brake pads, please contact your nearest AJ1 dealer for assistance, or schedule your motorcycle for servicing.
BLEEDING THE BRAKE SYSTEM
Because the brake system utilizes fluid, any air bubbles inside the brake system will cause you to lose braking efficiency. Air generally enters the brake system when the motorcycle sits unused for long periods of time. Air will also enter the system if you have a leaking brake hose, brake caliper or master cylinder. A brake system with air will cause the brake lever and pedal to feel soft and spongy. Use the procedure below to bleed air from both the front and rear brake system.
ADDING BRAKE FLUID (Front)
- Clean all dust and dirt from the bleeder screw
and remove the rubber screw cap.
- Slowly pump the brake lever or pedal slowly and firmly 4 – 6 times and then hold it (keep it in the pressed position).
- Using an 8mm bleeder wrench, loosen the bleeder screw located on the brake caliper. You will see brake fluid, and possibly some air will exit out of the bleeder screw.
- Once the fluid has stopped, tighten the bleeder screw and then slowly release the lever or pedal.
- Repeat steps 2 – 4 until all air bubbles have stopped flowing from the bleeder screw and only fluid is coming out. The lever/pedal should feel hard and firm when you are complete.
- If the fluid level in the master cylinder is going down, please remember to replenish the fluid until the air bleeding is done.