3.
13.
13. BRAKE SYSTEM MXU 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake pads and brake disk. • Drain the brake fluid from the hydraulic brake system before disassembly. • Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads. • Do not use brake fluid for cleaning. • Bleed air from the brake system if the brake system is removed or the brake is soft.
13. BRAKE SYSTEM MXU 250 FRONT HYDRAULIC BRAKE BRAKE PADS REMOVAL Remove the front wheel. (Öchapter 14) Remove the two brake pad pins from the brake caliper. Remove the two bolts attaching the brake caliper and then remove brake caliper. Brake Pad Pins Bolts Brake Caliper Holder Compress the brake caliper holder and remove brake pads. Brake Pads A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator.
13. BRAKE SYSTEM MXU 250 BRAKE DISK Measure the brake disk thickness. Service Limit: 3 mm (0.12 in) Measure the brake disk run out. Service Limit: 0.3 mm (0.012 in) INSTALLATION Reverse the “BRAKE PADS REMOVAL” procedures. FRONT BRAKE FLUID CHANGE/AIR BLEED BRAKE FLUID DRAINING Place the machine on the level ground and set the handlebar upright. Remove the two screws attaching the brake fluid reservoir cap.
13. BRAKE SYSTEM BRAKE FLUID REFILLING Connect a transparent hose and syringe to the brake caliper bleed valve and then loosen the bleed valve nut. Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the hose. Then, tighten the bleed valve nut. Torque: 0.6 kgf-m (6 Nm, 4.32 lbf-ft) ＊ • When drawing brake fluid with the syringe, the brake fluid level should be kept over 1/2 of the brake reservoir height.
13. BRAKE SYSTEM MXU 250 Fluid Tube Bolt BRAKE MASTER CYLINDER DISASSEMBLY Remove the brake reservoir cover Drain the brake fluid from the hydraulic brake system. (Ö13-4) ＊ Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts. Stop Light Switch Wire Remove fluid tube bolt and then disconnect the fluid tube.
13. BRAKE SYSTEM MXU 250 Master Cylinder Spring Main Piston Remove the washer, main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Snap Ring INSPECTION Check the cylinder inside wall, and spring for scratch, corrosion or other abnormal condition. If any abnormal condition is found, replace the inner parts or master cylinder.
13. BRAKE SYSTEM MXU 250 ASSEMBLY Before assembly, apply brake fluid to all removed parts. ＊ • During assembly, the main piston and spring must be installed as a unit without exchange. • When assembling the piston, soak the cups in brake fluid for a while. • Install the cups with the cup lips facing the correct direction. Install the main piston, spring and snap ring. Install the rubber cover. Install the brake lever.
13. BRAKE SYSTEM MXU 250 FRONT BRAKE CALIPER REMOVAL Remove the front wheel. (Ö chapter 14) First drain the brake fluid from the hydraulic brake system. (Ö13-4) Remove the brake pad pins. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper. Brake Pad Pins Bolts DISASSEMBLY Remove the brake pads. (Ö13-3) Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper.
13. BRAKE SYSTEM MXU 250 Push the piston dust seal inward to remove. Dust Seal Pushing the piston oil seal outward to remove it. Inner Oil Seal Clean the seals groove with brake fluid. ＊ Be careful not to damage the piston surface. INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper.
13. BRAKE SYSTEM ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the oil seal and dust seal. Install the brake caliper piston with grooved side facing out. ＊ Install the piston with its outer end protruding 3～5 mm beyond the brake caliper. Wipe off excessive brake fluid with a clean shop towel. Install the caliper spring plate into the caliper.
. BRAKE SYSTEM MXU 250 Brake Pad Cover REAR HYDRAULIC BRAKE Cotter Pin REAR BRAKE PADS REMOVAL Remove the brake pads cover. Remove the cotter pin and then pull out the brake pad pin from the caliper. Brake Pad Pin Brake Pads Remove the brake spring plate and then remove brake pads. Spring Plate Spring Plate Big End INSTALLATION Reverse the “REAR BRAKE PADS REMOVAL” procedures. ＊ • Make sure put the spring plate big end on the rear caliper.
13. BRAKE SYSTEM BRAKE FLUID DRAINING MXU 250 Reservoir Cover (Pedal) Place the machine on the level ground. Remove the two screws attaching the brake fluid reservoir cap (brake lever and brake pedal). ＊ Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Reservoir (Front Left Lever) Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose.
13. BRAKE SYSTEM MXU 250 Reservoir Cover (Pedal) Recommended Brake Fluid: DOT-4 Reservoir (Pedal) Reservoir Protection Cover Brake Pedal Bleed Valve (Pedal) BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake lever (pedal) after continuously pull it several times. Then, loosen the bleed valve nut to bleed air from the brake system. Repeat these steps until the brake system is free of air.
13. BRAKE SYSTEM MXU 250 REAR BRAKE MASTER CYLINDER (REAR BRAKE PEDAL) REAR MASTER CYLINDER ON THE LEFT HANDGRIP DISASSEMBLY Refer to the “FRONT BRAKE MASTER CYLINDER DISASSEMBLY” section in the chapter 13. ASSEMBLY Refer to the “FRONT BRAKE MASTER CYLINDER ASSEMBLY” section in the chapter 13. Upper Nut REAR MASTER CYLINDER ON THE REAR BRAKE PEDAL DISASSEMBLY Remove the brake reservoir cover. Drain the brake fluid from the hydraulic brake system. (Ö13-13) Loosen the upper and lower nuts.
13. BRAKE SYSTEM Remove the screw and remove the fluid inlet duct. Check the O-ring for wear or damage and replace if necessary. MXU 250 Screw Fluid Inlet Duct O-ring Seal Boot Remove the two nuts and remove the seal boot. Nuts Remove the circlip and then pull out the push rod, washer, piston and spring.
13. BRAKE SYSTEM INSPECTION Check the cylinder inside wall, and spring for scratch, corrosion or other abnormal condition. If any abnormal condition is found, replace the inner parts or master cylinder. Before assembly, inspect the lst and 2nd rubber cups for wear. MXU 250 Spring Piston ASSEMBLY Before assembly, apply brake fluid to all removed parts. ＊ During assembly, the master cylinder, piston and spring must be installed as a unit without exchange.
13. BRAKE SYSTEM MXU 250 REAR BRAKE CALIPER REMOVAL Drain brake fluid of both the rear brake side and the combination brake side. (Ö13-13) ＊ To prevent brake fluid from splashing on the parts nearby, cover the parts with cloth. Remove the brake pads. (Ö13-12) Remove the caliper mounting bolts and remover the caliper. Bolts ＊ Slightly loosen the caliper housing bolts before removing the caliper mounting bolts to facilitate later disassembly. Remove the caliper housing bolts.
13. BRAKE SYSTEM Remove the dust seals and piston seals. ＊ MXU 250 Seals Use care not to cause scratch on the cylinder bore. Do not reuse the piston seal and dust seal that have been removed. Piston INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper. BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0 mm (0.12 in) Measure the brake disk run out. Service Limit: 0.3 mm (0.
13. BRAKE SYSTEM MXU 250 ASSEMBLY Reassemble the caliper in the reverse order of disassembly procedures and observe the following points. ＊ Wash the caliper components with fresh brake fluid before assembly. Do not wipe off brake fluid after washing the components. Replace the piston seal and dust seal with new ones with brake fluid applied. Brake fluid specification and classification: DOT4 Fit the O-ring. Install and tighten the caliper housing bolts. Torque: 2.
