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18. HYDRAULIC BRAKE

SERVICE INFORMATION······················ 18-2 FRONT MASTER CYLINDER················· 18-8

TROUBLESHOOTING ·························· 18-2 REAR MASTER CYLINDER·················· 18-10

COMPONENT LOCATION ····················· 18-3 FRONT BRAKE CALIPER ···················· 18-12

BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER······················ 18-14

AIR BLEEDING ··································· 18-5
BRAKE PEDAL ·································· 18-15
BRAKE PAD/DISC ······························· 18-7

18

18-1
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HYDRAULIC BRAKE
SERVICE INFORMATION
HYDRAULIC BRAKE

GENERAL

Frequent inhalation of brake 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.

Spilling brake fluid will severely damage instrument lenses and painted surface. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cover; make sure the front reservoir is horizontal first.
• This section covers service of the conventional brake components of the brake system. For Anti-lock Brake System (ABS)
service (page 19-2).
• This models is equipped with the ABS, however, the brake fluid replacement procedure is performed in the same manner as in
the ordinary air bleeding procedure. Note that replacement and bleeding air from the brake fluid in the ABS modulator is not
necessary, as it sealed in the modulator.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they
may not be compatible.
• 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 check brake operation before riding the motorcycle.
• When the wheel speed sensor is removed, be sure to check the air gap between the wheel caliper bracket and pulser ring after
installing it (page 19-22).

TROUBLESHOOTING
Brake lever/pedal soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seal
• Worn master piston cups
• Worn brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master piston
• Bent brake lever/pedal
Brake lever/pedal hard
• Clogged/restricted fluid passage
• Sticking/worn caliper piston
• Caliper not sliding properly
• Worn caliper piston seal
• Sticking/worn master piston
• Bent brake lever/pedal
Brake drags
• Contaminated brake pad/disc
• Misaligned wheel
• Badly worn brake pad/disc
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted fluid passage
• Sticking caliper piston

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HYDRAULIC BRAKE
COMPONENT LOCATION
FRONT:

12 N·m (1.2 kgf·m, 9 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

17 N·m (1.7 kgf·m, 13 lbf·ft)

CMX500A only

30 N·m (3.1 kgf·m, 22 lbf·ft)

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HYDRAULIC BRAKE
REAR:

12 N·m (1.2 kgf·m, 9 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

37 N·m (3.8 kgf·m, 27 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

17 N·m (1.7 kgf·m, 13 lbf·ft)

22 N·m (2.2 kgf·m, 16 lbf·ft)

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HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
For front brake: Turn the handlebar so the reservoir is level.
[2]
Remove the following: [1]
– two screws [1] [3]
– reservoir cap [2]
– set plate [3]
– diaphragm [4]

[4]

Take care not to Remove the following:

spill the fluid out of [4]
– reservoir mounting bolt [1]
the reservoir.
– reservoir cover [2] [5]
– brake hose stay [3]
– two screws [4] [6]
– reservoir cap [5]
– set plate [6]
– diaphragm [7] [7]
Temporarily install the reservoir [8] onto the battery [2]
case with the mounting bolt secure it so the reservoir is
level. [8]

[1] [3]

Connect a bleed hose [1] to the caliper bleed valve [2]. Front: Rear:
[2]
Loosen the bleed valve and pump the brake lever or
pedal until no more fluid flows out of the bleed valve. [1]
[2]
Close the bleed valve.

[1]

18-5
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HYDRAULIC BRAKE
BRAKE FLUID FILLING/AIR BLEEDING
Fill the reservoir to the upper level line [1] with DOT 4 Front: Rear:
brake fluid from a sealed container. [1]
Connect a commercially available brake bleeder to the [1]
bleed valve.
Operate the brake bleeder and loosen the bleed valve.
Check the fluid level If an automatic refill system is not used, add fluid when
often while bleeding the fluid level in the reservoir is low.
to prevent air from
Perform the bleeding procedure until the system is
being pumped into
completely flushed/bled.
the system.
Close the bleed valve and operate the brake lever or
pedal. If it still feels spongy, bleed the system again.

If the brake bleeder is not available, use the following

procedure.
Connect a bleed hose to the bleed valve.
Pump up the system pressure with the brake lever/
pedal until the lever/pedal resistance is felt.
Do not release the 1. Squeeze the brake lever or depress the brake pedal
brake lever or pedal all the way, and loosen the bleed valve 1/4 of a turn.
until the bleed valve Wait several seconds and then close it.
has been closed. 2. Release the brake lever/pedal slowly and wait
several seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the system completely, tighten the bleed
valve to the specified torque.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
Fill the reservoir to the upper level line with DOT 4
brake fluid.
For front brake: Install the diaphragm, set plate, reservoir cap and
tighten the screws to the specified torque.
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
For rear brake: Carefully remove the reservoir [1] from the battery case
by removing the mounting bolt [2]. [6]

Take care not to Install the diaphragm [3], set plate [4], reservoir cap [5] [5]
spill the fluid out of and tighten the screws [6] to the specified torque.
the reservoir. [4]
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Set the brake hose stay [7] to the brake hose.
[3]
Install the reservoir, cover [8] and tighten the mounting
bolt. [8]
[1]

[2]
[7]

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HYDRAULIC BRAKE
BRAKE PAD/DISC
BRAKE PAD REMOVAL/
INSTALLATION

Check the fluid • If you replace the brake pads with new ones, push
level in the the caliper pistons all the way in by pushing the
reservoir as this caliper body inward to allow installation of new brake
operation causes pads before removing the pads.
the fluid level to Always replace the brake pads in pairs to ensure
rise. even disc pressure.
FRONT
Do not operate the Remove the pad pin [1] by pushing the pads against the
brake lever after pad spring, then the brake pads [2] out of the caliper.
removing the pads.

[1]
[2]

Make sure the pad spring [1] is installed in position [4]

(page 18-13).
Be sure the stopper ring [2] on the pad pin is in good
[2]
condition, and replace it with a new one if necessary.
Coat the stopper ring with silicone grease.
Install the pads [3] so that their ends are set in the [5]
retainer [4] properly.
Install the pad pin [5] by pushing the pads against the [1]
pad spring to align the pad pin holes in the pads and
caliper body.
Tighten the pad pin to the specified torque.
TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft) [3]

Operate the brake lever to seat the caliper pistons

against the pads.

REAR
Loosen the pad pin [1] and remove the caliper bolt [2].
Do not operate the Pivot the caliper body up, and remove the pad pin and [3]
brake pedal after brake pads [3].
removing the pads.

[1] [2]

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HYDRAULIC BRAKE
Make sure the pad spring [1] is installed in position
[1]
(page 18-14).
Be sure the stopper ring [2] on the pad pin is in good
condition, and replace it with a new one if necessary.
Coat the stopper ring with silicone grease.
Install the pads [3] so that their ends are rest on the pad
retainer [4] properly.
Lower the caliper body and loosely install a new caliper
bolt [5].
Install the pad pin [6] by pushing the pads against the
pad spring to align the pad pin holes in the pads and
caliper body. [4]
Tighten the caliper bolt to the specified torque.
[2]
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) [3]
Tighten the pad pin to the specified torque. [6]
TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)
Operate the brake pedal to seat the caliper piston
against the pads.

[5]

BRAKE DISC INSPECTION

Visually inspect the brake disc for damage or cracks.
Measure the brake disc according to HYDRAULIC
BRAKE SPECIFICATIONS (page 1-10) and replace if
necessary.

FRONT MASTER CYLINDER

REMOVAL/INSTALLATION
Drain the brake fluid from the front brake hydraulic
system (page 18-5).
[3]
When removing the Remove the following:
oil bolt, cover the
– right rearview mirror (page 2-5)
end of the brake [2]
– brake light switch connectors [1]
hose to prevent
– oil bolt [2]
contamination.
– sealing washers [3]
– brake hose [4]

[4]

[1]

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HYDRAULIC BRAKE
– two socket bolts [1]
– master cylinder holder [2] [3] Align
– master cylinder [3]
Installation is in the reverse order of removal.

[4]
• Replace the sealing washers with new ones.
• Install the master cylinder holder with the "UP" mark
[4] facing up.
• Align the edge of the master cylinder with the punch
mark on the handlebar, and tighten the upper bolt
first then tighten the lower bolt.
• Be sure to set the eyelet joint into the groove when
connecting the brake hose. [2] [1]
TORQUE:
Front master cylinder holder socket bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Oil bolt: 34 N·m (3.5 kgf·m, 25 lbf·ft)
Fill and bleed the front brake hydraulic system (page
18-6).

DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front master cylinder as
shown in the following illustration.
• Do not allow the piston cup lips to turn inside out.
• Install the snap ring with the chamfered edge facing
the thrust load side and be certain it is firmly seated
in the groove. Do not reuse the snap ring which
could easily spin in the groove.
• Align the switch boss with the master cylinder hole
properly.
• When tightening the pivot nut, hold the pivot bolt
securely.

SECONDARY PRIMARY PISTON PIVOT BOLT

PISTON CUP CUP (Grooves) 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
BOOT

0.10 g (0.004 oz)

MASTER CYLINDER

SNAP RING

MASTER PISTON
SPRING

BRAKE LIGHT SWITCH

BRAKE LEVER

PIVOT NUT BRAKE LIGHT SWITCH SCREW

0.10 g (0.004 oz)
5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

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HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– master cylinder
– master piston
– piston cups
– spring
– boot
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-10) and replace if
necessary.

REAR MASTER CYLINDER

REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
system (page 18-5).
Remove the rear brake reservoir (page 18-6). [1] [4]

When removing the Disconnect the brake hose [1] by removing the oil bolt
oil bolt, cover the [2] and sealing washers [3].
end of the brake
Support the right rider footpeg bracket [4] securely and
hose to prevent
remove the bracket bolts [5].
contamination.

[5] [2]
[3]

Remove the following.

– cotter pin [1] [1] [3]
– joint pin [2]
– mounting bolts [3]
– master cylinder [4]
Installation is in the reverse order of removal.

• Replace the sealing washers and cotter pin with new

ones. [2]
• Be sure to rest the eyelet stopper pin against the
stopper when tightening the oil bolt.

TORQUE: [4]
Rider footpeg bracket bolt:
37 N·m (3.8 kgf·m, 27 lbf·ft)
Rear master cylinder mounting bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)
Fill and bleed the rear brake hydraulic system (page 18-
6).

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HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear master cylinder as
shown in the following illustration.
• Adjust the push rod length between the center of the
lower mounting bolt hole and center of the joint pin
hole when installing the push rod joint.
• Do not allow the piston cup lips to turn inside out.
• Install the snap ring with the chamfered edge facing
the thrust load side and be certain it is firmly seated
in the groove. Do not reuse the snap ring which
could easily spin in the groove.

SNAP RING PUSH ROD

JOINT

0.4 g (0.014 oz)

O-RING
SNAP RING

JOINT PIPE
0.4 g (0.014 oz)
BOOT
SNAP RING

BOOT

PUSH ROD JOINT NUT

17 N·m (1.7 kgf·m, 13 lbf·ft)
MASTER CYLINDER

SPRING

MASTER PISTON

PUSH ROD ASSEMBLY BRAKE ROD JOINT

When the push rod has been disassembled, adjust the

push rod length so that the distance from the center of
the master cylinder lower mounting bolt hole to the [2]
center of the joint pin hole is standard length as shown.
If the length is adjusted to the longer position, make [1]
sure that the lower end of the push rod thread [1] is
visible inside the joint.
After adjustment, tighten the joint nut [2] to the specified 64.0 – 66.0 mm
torque. (2.52 – 2.60 in)
TORQUE:
Rear master cylinder push rod joint nut:
17 N·m (1.7 kgf·m, 13 lbf·ft)

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HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– master cylinder
– master piston
– piston cups
– spring
– boot
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-10) and replace if
necessary.

FRONT BRAKE CALIPER

REMOVAL/INSTALLATION
Drain the brake fluid from the front brake hydraulic [3]
system (page 18-5). [1]

Remove the following: [2]

When removing the – oil bolt [1]

oil bolt, cover the – sealing washers [2] [6]
[5]
end of brake hose to – brake hose [3]
prevent – sensor mounting bolt (CMX500A) [4]
contamination. – sensor wire guide blot (CMX500A) [5]
– brake caliper mounting bolts [6]
– brake caliper [7] [7]
– front wheel speed sensor (CMX500A) [8]
Installation is in the reverse order of removal.
[4] [8]
• Replace the brake caliper mounting bolts and
sealing washers with new ones.
• Be sure to rest the eyelet stopper pin against the
caliper body when tightening the oil bolt.
• Before installing the wheel speed sensor, wipe the
sensor tip and mounting area to remove any foreign
material.
• Always replace the front wheel speed sensor bolt
with a new one.

TORQUE:
Front brake caliper mounting bolt:
30 N·m (3.1 kgf·m, 22 lbf·ft)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)
Fill and bleed the rear brake hydraulic system (page 18-
6).

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HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front brake caliper as
shown in the following illustration.
For brake pad removal/installation (page 18-7).
• Mark the pistons to ensure that they are reinstalled
in their original locations.
• When removing the caliper pistons with compressed
air, place a shop towel over the pistons to prevent
damaging the pistons and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
• Install the pistons with the opening toward the pads.

0.4 g (0.01 oz) CALIPER PIN BOOT

CALIPER PIN DUST SEAL CALIPER BRACKET

22 N·m (2.2 kgf·m, 16 lbf·ft)
PAD RETAINER*
PISTON SEAL
BLEED VALVE
5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) 0.4 g (0.01 oz)

STOPPER RING
CALIPER PISTON

PAD SPRING:

PAD SPRING
BRAKE PAD PIN BRAKE PADS
17 N·m (1.7 kgf·m, 13 lbf·ft) BRACKET PIN
BOOT
*Apply Honda Bond A or equivalent to the retainer seating surface.

INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– caliper cylinders
– caliper pistons
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-10) and replace if
necessary.

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HYDRAULIC BRAKE
REAR BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic [3]
system (page 18-5). [1]
When removing the – oil bolt [1]
oil bolt, cover the – sealing washers [2]
end of brake hose to – brake hose [3]
prevent – brake caliper [4]
contamination. – caliper pin boot [5] [5]
[6]
Installation is in the reverse order of removal.

• Replace the and sealing washers with new ones. [2]

• If the pad retainer [6] was removed, apply Honda
Bond A or equivalent to the retainer seating surface.
• Apply 0.4 g of silicone grease to the sliding area of [4]
the caliper pin bolt.
• Be sure to rest the eyelet stopper pin against the
caliper body when tightening the oil bolt.

TORQUE: Oil bolt: 34 N·m (3.5 kgf·m, 25 lbf·ft)

Fill and bleed the rear brake hydraulic system (page 18-
6).

DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear brake caliper as
shown in the following illustration.
• When removing the caliper piston with compressed
air, place a shop towel over the piston to prevent
damaging the piston and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
• Install the piston with the opening toward the pads.

BLEED VALVE
DUST SEAL 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
PISTON SEAL

0.4 g (0.01 oz)

CALIPER PISTON
CALIPER PIN BOLT
27 N·m (2.8 kgf·m, 20 lbf·ft)

STOPPER RING

PAD SPRING:
BRAKE PAD PIN
17 N·m (1.7 kgf·m, 13 lbf·ft)

CALIPER SLEEVE
SLEEVE BOOT
BRAKE PADS
PAD SPRING
0.4 g (0.01 oz)

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HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– caliper cylinder
– caliper piston
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-10) and replace if
necessary.

BRAKE PEDAL
REMOVAL/INSTALLATION
Remove the right side cover (page 2-4).
Support the right rider footpeg bracket [1] securely and
remove the bracket bolts [2]. [1]

[2]

Remove the following:

[1]
– switch spring [1] [4]
– cotter pin [2] [6]
– joint pin [3]
– snap ring [4]
– washer [5]
– brake pedal [6]
Installation is in the reverse order of removal.

[3]
• Apply grease to the pedal pivot sliding area (grease
groove).
• Install the snap ring with the chamfered edge facing
the thrust load side and be certain it is firmly seated [2] [5]
in the groove. Do not reuse the snap ring which
could easily spin in the groove.
• Replace the cotter pin with a new one.
• Install the each spring in the direction as shown.

TORQUE:
Rider footpeg bracket bolt:
37 N·m (3.8 kgf·m, 27 lbf·ft)

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MEMO