SECTION 4 BRAKE SYSTEM

Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1

Group 2 Operational checks and troubleshooting ------------------------------------------------------ 4-5
Group 3 Tests and adjustments ----------------------------------------------------------------------------------- 4-7

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 SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION

1. OUTLINE
There are two brake systems, the service brake system and the parking brake system.
In the service brake system, oil pressure is generated in the master cylinder by treading on the brake
pedal. This pressure causes the brake lever to press the pressure pin which gives braking pressure to
the disk carrier.
In the parking brake system, the brake lever is operated by cable. Therefore the pressure pin makes
braking pressure onto the disk carrier.

2. SPECIFICATION

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1) BRAKE
Item Unit Specification
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Type - Wet disc brake
Brake fluid - Hydraulic oil ISO VG32 (AZOLLA ZS32)
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Max. torque N.m (at 30 bar) 3700
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2) PARKING BRAKE
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Item Specification
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Type Ratchet, internal expanding mechanical type

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Parking lever stroke 12.1ä

Parking cable stroke 60 mm
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4-1
3. BRAKE PEDAL AND PIPING

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22B9BS01

1 Brake pedal & bracket assy 3 Reservoir tank assy

2 Parking lever assy 4 Brake master cylinder

4-2
4. CONNECTING THE BRAKE
We recommend to use a two-stage output cylinder for the service brake. Advantage compared to a
single stage cylinder : the pedal stroke can be as small as possible.
Three connections M10Ý1 are provided for connecting the hydraulic brake system and the brake
cable.
1) CONNECTING THE HYDRAULIC BRAKE SYSTEM
Connect the bleeder and the brake hose(hydraulic line) according to the assembly position.
ÂTightening torque : 1.2~1.6 kgfÂm (9~12 lbfÂft)
When placing the hydraulic lines, the bending radii should be kept as large as possible to keep the
resistance against the restoring forces for lifting the break as small as possible.
2) CONNECTING THE PARKING BRAKE CABLE
Screw the parking brake cable into the lever.

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Check and maintain the installation dimensions when the installation has been finished.
When placing the brake cable, the bending radii should be kept as large as possible to keep the
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resistance against restoring forces of the brake as small as possible.
Bleed the brake system after filling of brake fluid. Refer to page 4-7.
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22B9BS10

1 Housing 5 Bleeding valve

2 Gear drive shaft 6 Air breather
3 Parking lever 7 Final housing
4 Brake port 8 Wheel hub

4-3
5. BRAKE MASTER CYLINDER
1) STRUCTURE

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12 4
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19 11

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1 15
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18 17
20
14

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22B7BS09

1 Body 6 Plate 11 Union 16 Head pin

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2 Piston 7 Snap ring 12 Union bolt 17 Nut

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3 Secondary cup 8 Boot 13 Washer 18 Seat

4 Primary cup 9 Spacer 14 Rod 19 Cap
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5 Spring 10 Spring seat 15 Head 20 Cap

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2) DISASSEMBLY
(1) Remove the master cylinder boot (8) and remove the rod (14).
(2) Remove the snap ring (7) and take out the plate (6), the piston (2), the piston primary cup (4), and
piston spring (5).
(3) Specification of master cylinder.
ÂCylinder bore diameter : 19.05 mm
ÂPiston stroke : 23.0 mm
3) INSPECTION
(1) Clean and check these components.
ö Use isopropyl alcohol or brake fluid for washing the components. Do not use gasoline, kerosene or any
other mineral oils. When using alcohol, do not leave rubber parts in the liquid for more than 30 seconds.
(2) Inspect the inside wall of the master cylinder, and if any faults are found, replace the cylinder assembly.
(3) Replace the boot (8), the primary cup (4), piston(2), if deformation or any other defect is found.
4) ASSEMBLY
ö Prior to assembly make sure again of no contaminant of the components. Apply a thin coat of
brake oil to the components.
ÂAssembly is in opposite order to disassembly.

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