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RX4 Brakes Maintenance

Testing Page.html

RX4 Drive Train Tutorial

General Service Information

  • Keep grease and oil off brake pads and rotors
  • Discard contaminated brake pads and clean rotors with degreaser
  • Brake dust may contain asbestos fibers
  • Do not clean brake dust with compressed air
  • Do not allow water, dirt or other contaminates to enter the hydraulic brake system
  • If brake lever or pedal feels spongy, system needs to be bled.
  • Only use fresh DOT 3 or 4 brake fluid from a sealed container
  • After servicing wheels, brakes or suspension always verify brake function before riding
  • When servicing wheels, suspension or steering, lift motorcycle with suitable work stand
 
EMISSION RELATED ITEMS
MILES(x)1K		    FIRST SERVICE
500		 
2.5K		 
5K		 
7.5K		 
10K		 
12.5		 
 15K		 
 17.5		 
 20K
FUEL LINE * I   I   I   I   I
FUEL FILTER *     R   R   R   R
THROTTLE OPERATION * I   I   I   I   I
AIR CLEANER       I   I   I   I
SPARK PLUG       I   I   R   I
VALVE CLEARANCE *     I   I   I   I
ENGINE OIL   R R R R R R R R R
ENGINE OIL FILTER   R R R R R R R R R
RADIATOR COOLANT       I   I   R   I
COOLING SYSTEM *     I   I   I   I
EVAPORATIVE EMISSION CONTROL SYSTEM *     I  
 		 I   I   I
NON-EMISSION RELATED ITEMS
MILES(x)1K		 
FIRST SERVICE
500
 
 2.5K		 
5K		 
 7.5		 
10K
12.5		 
 15K		 
17.5		 
 20K
DRIVE CHAIN   I I I I I I I I I
BATTERY   I I I I I I I I I
BRAKE FLUID     I I I I I R I I
BRAKE PAD WEAR     I I I I I I I I
BRAKE SYSTEM   I   I   I   I   I
BRAKE LIGHT SWITCH * I   I   I   I   I
HEADLIGHT AIM * I   I   I   I   I
CLUTCH SYSTEM   I   I   I   I   I
SIDE STAND   I   I   I   I   I
SUSPENSION * I   I   I   I   I
NUTS, BOLTS, FASTENERS   I I I I I I I I I
WHEELS/TIRES ** I I I I I I I I I
STEERING HEAD BEARINGS ** I   I   I   I   I

 
 

 
Specifications

Standard Torque Values

Bolt SizeTorque
5 mm
6 mm
8 mm  
10 mm
12 mm		 5.2 mn (3.8 ft lbs)
10 nm (7 ft lbs)
22 nm (16 ft lbs)
34 nm (25 ft lbs)
54 nm (40 ft lbs)

 
Front Wheel
Rim- 2.15 x 19 in
Tire- 110/80R19, 
Cold tire pressure- 36 psi
Wheel runout- 2 mm (0.08 in) Axial/Radial
Axle torque- 106 nm (78 ft lbs)
Axle runout- 0.02 mm (0.008 in)
Spoke nipple size- 6 mm
Spoke nipple torque- 3.7 nm (32.7 in lbs)
 
Rear wheel
Rim- 4.25 x 17 in
Tire- 150/70R17
Cold tire pressure- 36 psi
Wheel runout- 2 mm (0.08 in) Axial/Radial
Axle torque- 106 nm (78 ft lbs)
Axle runout- 0.02 mm (0.008 in)
Spoke nipple size- 6 mm
Spoke nipple torque- 3.7 nm (32.7 in lbs)
Rear Sprocket- 44 teeth
Chain- 530 x 108 links
Drive chain slack- 25-35 mm (1.0-1.4 in)

Front Fork
Stanchion diameter- 41 mm
Suspension travel- 130 mm (5.1in)
Rebound dampening adjustment- 16 clicks
Fork oil weight- 5w suspension fluid
 
Rear Shock
Eye to eye length- 44 cm (17.3 in)
Suspension travel- 120 mm (4.7 in)
Rebound dampening adjustment- 6 clicks
Damper gas pressure- 150 psi
 
Front Brake
Minimum pad thickness- 1 mm (wear indicator)
Minimum rotor thickness- 3 mm
Mounting bolt torque- (22 ft lbs)
Brake fluid- DOT 3 or 4
 
Rear Brake
Minimum pad thickness- 1 mm (wear indicator)
Minimum rotor thickness- 3 mm
Mounting bolt torque- (22 ft lbs)
Brake fluid- DOT 3 or 4




Troubleshooting
 
Hard steering

  • Steering stem adjusted to tight
  • Damaged steering head bearings
  • Inadequate lubrication in steering head bearings
  • Low tire pressure
 
Steers to one side or does not track straight
  • Front wheel installed incorrectly
  • Misaligned rear wheel
  • Loose axle
  • Loose front axle pinch bolts
  • Worn wheel bearings
  • Worn swingarm bearings
  • Bent axle
  • Bent fork tube
 
Wheels wobble
  • Loose axle
  • Loose front axle pinch bolt
  • Wheels out of balance
  • Faulty tire
  • Bent rim
  • Bent spokes
  • Worn wheel bearings
 
Brake lever/pedal soft of spongy
  • Air in brake hydraulic system
  • Leak in hydraulic brake system
  • Misadjusted brake lever/pedal
  • Worn seals in master cylinder
  • Worn seals in caliper
  • Clogged passages in brake hydraulic system
  • Low fluid
  • Contaminated brake pads or rotors
  • Warped rotor
  • Bent or worn brake lever/pedal       
Brakes
 
TROUBLESHOOTING | BRAKES
 
If brake lever/pedal soft or spongy, these are possible causes:
  • Air in brake hydraulic system
  • Leak in hydraulic brake system
  • Misadjusted brake lever/pedal
  • Worn seals in master cylinder
  • Worn seals in caliper
  • Clogged passages in brake hydraulic system
  • Low fluid
  • Contaminated brake pads or rotors
  • Warped rotor
  • Bent or worn brake lever/pedal
 
Servicing Front and Rear Brakes
 
  • Fluid inspection- When the fluid is low in the master cylinder reservoir, check the brake pads for wear. As the brake pads wear the caliper pistons are pushed out and displaces fluid from the master cylinder.
  • If the fluid is low and the pads are not worn check for leaks.
  • If the pads are near minimum thickness, replacement is necessary.
  • Keep grease and oil off brake pads and rotors
  • Discard contaminated brake pads and clean rotors with degreaser
  • Brake dust may contain asbestos fibers
  • Do not clean brake dust with compressed air
  • Do not allow water, dirt or other contaminates to enter the hydraulic brake system
  • If brake lever or pedal feels spongy, system needs to be bled.
  • Only use fresh DOT 3 or 4 brake fluid from a sealed container
  • Always replace brake pads as pairs to unsure even pressure
  • After servicing wheels, brakes or suspension always verify brake function before riding
 
To bleed hydraulic system the use of a commercially available brake bleeder is highly recommended.
  1. Connect the brake bleeder to the bleed valve on the caliper
  2. Position the master cylinder reservoir as level as possible. Position rags to prevent spills. DOT 3 / 4 brake fluid is corrosive and will damage painted surfaces.
  3. Remove cover and fill master cylinder reservoir
  4. Activate brake bleeder and loosen the bleed valve. Add fluid to reservoir, do not let fluid run dry.
  5. Close bleed valve
  6. Slowly pump up pressure in master cylinder until no air bubbles are seen floating up to the surface in the reservoir
  7. Perform procedure until the brake fluid is flushed and bleed. Repeat if necessary.
 
Replacing Front Pads
 
Step 1: Place motorcycle on suitable work stand
 
Step 2: Replace pads one caliper at a time
 
Step 3: Remove the front caliper mounting bolts
 
Step 4: With a clean large flat screwdriver spread the brake pads completely apart. This will compress the pistons to make room for the new pads.
 

Step 5: Remove the brake pad pins and pads
 

 
Step 8: Verify caliper locating dowels are in place
 


Step 6: When installing new pads:
  • Do not contaminate pads with grease or oil
  • Push pads against the retainer springs and install pad pins
  • Verify pads are parallel in the caliper
  • Torque caliper bolts to 30 nm (22 ft lbs) (use medium strength thread locker)
  • Flush and bleed brake fluid
Step 7: Verify front brake function before riding
 
Replacing Rear Pads
 
Step 1: Place motorcycle on suitable work stand
 
Step 2: Remove rear caliper mounting bolts and remove caliper
 

 
Step 3: With a clean large flat screwdriver spread the brake pads completely apart. This will compress the pistons to make room for the new pads.
 
Step 4: Remove the brake pad pin cover, pad pin and pads
 
Step 5: Install new pads in retaining slot on carrier
 

 
Step 6: Install caliper over pads and line up mounting bolts. Install front bolt first. Install rear bolt then pad pin.
 
Step 7: When installing new pads
  • Do not contaminate pads with grease or oil
  • Torque caliper bolts to 30 nm (22 ft lbs) (use medium strength thread locker)
  • Verify pads are in retaining slot on carrier
  • Flush and bleed brake fluid
  •  
Step 8: Verify rear brake function before riding