SYM 13.

BRAKE

MECHANISM DIAGRAM ................................13-1 BRAKE CALIPER .............................. 13-7

MAINTENANCE INFORMATION ....... 13-3 BRAKE DISK ..................................... 13-8
TROUBLE DIAGNOSIS ..................... 13-4 BRAKE MASTER CYLINDER ........... 13-8
HYDRAULIC BRAKE SYSTEM DRUM BRAKE-DRUM ....................... 13-11
INSPECTION ..................................... 13-5 BRAKE LING ..................................... 13-11
BRAKE FLUID REPLACEMENT/ BRAKE PANEL.................................. 13-12
AIR-BLEED ........................................ 13-6
MECHANISM DIAGRAM
Front Disk Brake System

3.3~3.7 kgf-m
0.8~1.0 kgf-m

2.8~3.2 kgf-m

4.0~4.5 kgf-m

11.0~13.0 kgf-m

13-1
13. BRAKE SYM

Rear Drum Brake System

0.8~1.2 kgf-m

0.8~1.2 kgf-m

13-2
SYM 13. BRAKE

MAINTENANCE INFORMATION
Precautions in Operation
Caution
Installing pad dusts may cause disorders of respiration system or cancer, therefore, never
use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool
instead.

The brake caliper can be removed without removing the hydraulic system.
After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the
hydraulic system.
While refilling brake fluid, care should be taken not to let the foreign material entering into
the brake system.
Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
Check the operation of the brake system before you go.

Specifications Unit: mm
Item Standard Limit
The thickness of front brake 3.50 2.00
disk
Front brake disk eccentricity 0.15 0.30
Master cylinder inner diameter 25.40 ─

ID of front & rear brake drums 130.00 131.00

OD of front brake disk 130.00 ─

Thickness of front disk brake ─ As brake ling mark

pad
Thickness of front drum brake ─ 2mm or As brake ling mark
pad

Thickness of rear brake pad ─ 2mm or As brake ling mark

Torque values
Bolt for front brake arm 0.8~1.2kgf-m
Bolt for rear brake arm 0.8~1.2kgf-m
Brake hose bolt 3.3~3.7kgf-m
Bolt for brake caliper 3.1~3.5kgf-m
Air-bleed valve 0.8~1.0kgf-m

13-3
13. BRAKE SYM

TROUBLE DIAGNOSIS
DISK BRAKE
Soft brake lever Uneven brake
Air inside the hydraulic system Dirty brake pad/disk
Hydraulic system leaking Poor wheel alignment
Worn master piston Clogged brake hose
Worn brake pad Deformed or warped brake disk
Poor brake caliper Restricted brake hose and fittings
Worn brake pad/disk
Low brake fluid Tight brake
Blocked brake pipe Dirty brake pad/disk
Warp/bent brake disk Poor wheel alignment
Bent brake lever Deformed or warped brake disk

Hard operation of brake lever Brake noise

Blocked brake system Dirty pad
Poor brake caliper Deformed brake disk
Blocked brake pipe Poor brake caliper installation
Seized/worn master cylinder piston Imbalance brake disk or wheel
Bent brake lever

DRUM BRAKE
Poor brake performance Tight operation or low return speed of
Improper brake adjustment brake lever
Worn brake pad Worn/broken/crack return spring
Worn brake drum Worn drum
Worn brake cam Dirty brake pad
Improper brake pad installation Brake seized caused from dirty brake
Seized brake cable drum
Dirty brake pad Seized brake cable
Dirty brake drum Worn brake cam
Brake pad worn in brake cam area. Improper brake pad installation
Poor contact between brake arm and
camshaft indent Brake noise
Worn brake pad
Worn drum
Dirty brake pad
Dirty brake drum

13-4
SYM 13. BRAKE

HYDRAULIC BRAKE SYSTEM

Hose connection
INSPECTION
Inspection
Visual inspect for brake fluid leaking or
damage. Check if brake hose connection
loosen with wrench and turn the handlebar
from right to left motion or press down the
shock absorber to check if there is something
is interfered with the brake system or brake
components.

Brake disc
Operate the brake system and check the
brake pad. Check the front brake from front
side, and replace the brake pad with new one
when the brake pad wear limitation groove
reaches to the brake disk.

brake pad
wear limitation
groove
brake caliper
Park the motorcycle on a flat ground and
check its brake fluid level.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
CAUTION
The fluid level will not be correct if lower
parking the motorcycle in title or just level
parking. It has to waiting for around 3~5
minutes.
Never use faked brake fluid to prevent
from chemical reaction.
It has to apply with same brand brake
fluid to sure the brake performance.
Brake Fluid Add
Turn the handlebar to let the master cylinder master cylinder cap
in horizontal position before removed the
master cylinder cap.
Place a rag onto painting, plastic or rubber
components when conduct brake system
maintenance.
CAUTION
Do not over the upper level when adding
brake fluid and avoid to spilling brake fluid
on painted surfaces, plastic or rubber Lower level
components to result in their damages.

13-5
13. BRAKE SYM
Remove the master cylinder cap and
diaphragm. master
Add good quality brake fluid and it has to add cylinder
same brand brake fluid into the master cylinder.
Clean dirty brake disk. diaphragm
CAUTION
The dirty brake pad or disc will reduce the
brake performance. The mixed
non-compatible brake fluid will reduce brake
performance. Foreign materials will block
the system causing brake performance to
be reduced or totally lost.
BRAKE FLUID REPLACEMENT/
AIR-BLEED
Connect drain hose to drain valve. drain valve
Open the drain valve on the caliper and hold
and release the brake lever alternatively until
the old brake fluid is entirely drained out.
Close the drain valve and add specified brake
fluid into the brake master cylinder.
CAUTION
To reuse the spent brake fluid will effect
brake performance.
Connect one end of transparent hose to the
drain valve, and put the other end into a
container.
Open the drain valve around 1/4 turns, and at
the same time hold the brake lever until the
there is no air bubble in the drain hose and bubble
also feeling resistance on the brake lever. drain valve
Close the drain valve when finishing the
brake system refilling fluid procedure, and
operate the brake lever to check whether air
bubble is in brake system or not. If brake is
still soft, please bleed the system as
described below.
1. Tightly hold the brake lever and open the
drain valve around 1/4 turns, and then close
the valve.
CAUTION
Do not release the brake lever before the transparent draining hose
drain valve is closed.
Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air entering into the system.
2. Slowly release the brake lever, and wait for
a few seconds until it reaches its top
position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose. Tightly close
the drain valve.
4. Make sure the brake fluid is in the UPPER
level of the master cylinder, and refill the
fluid if necessary.
5. Cover the cap.

13-6
SYM 13. BRAKE

BRAKE CALIPER
Removal bolts x 2
Place a container under the brake caliper,
and loosen the brake hose bolt and finally
remove the brake hoses.
CAUTION
Do not spill brake fluid on painted
surfaces.
Remove two caliper bolts and the caliper.
hose bolt

Make sure the brake pad condition. Replace the

pad if the brake pad wear limitation groove brake pad wear
close to the brake disk. limitation groove
Brake Pad Replacement
Compress the caliper and let the brake pad out
of the caliper mounting plate. Compress the
brake pad locking spring. Remove the inner
brake pad firstly and then remove the outer
brake pad.
Compress the brake caliper at first as
installation. Install the inner brake pad firstly,
and then install the outer brake pad.
brake pad

brake mounting
INSTALLATION brake pad plate
Install the brake caliper and tighten the
attaching bolts securely.
Torque: 3.3 kgf-m
CAUTION
piston
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of
brake disc. brake
caliper
Tighten the pad guide bolt. locking spring
Torque: 1.8 kgf-m

Use two seal washers and hose bolts to lock

the hose and brake caliper in place.
Torque: 3.5 kgf-m

Refill up the brake fluid to the reservoir and

make necessary air bleeding.

13-7
13. BRAKE SYM

BRAKE DISK
Inspection
Visually check the brake disk for wear or
break.
Measure the thickness of the disk at several
places. Replace the disk if it has
exceeded the service limit.
Allowable limit: 2.0 mm brake disk

micrometer

Remove the brake disk from wheel.

Check the disk for deformation and bend.
Allowable limit: 0.30 mm
CAUTION
Do not let grease touch to the brake disc
that will cause brake performance.
Do not clean the brake pad with air gun.
Operator should wear mask & glove and
use vacuum cleaner to clean the brake
pad.

BRAKE MASTER CYLINDER

Removal
brake hose
CAUTION
Do not let foreign materials enter into the
cylinder.

CAUTION bolts x2
The whole set of master cylinder, piston,
spring, diaphragm and circlip should be
replaced after removal.
Remove the front and rear handlebar
guards. circlip
Remove the leads of brake lamp switch. rubber boot
Drain out the brake fluid. brake lamp
Remove the brake lever from the brake piston switch
master cylinder. rubber spring
Remove the brake hose.
Remove the master cylinder seat and the washer
master cylinder. master
Remove the rubber pad. cylinder
Remove the circlip.
Remove the piston and the spring.
Clean the master cylinder with
recommended brake fluid.

13-8
SYM 13. BRAKE

Inspection
Check the master cylinder for damage or master cylinder
scratch. Replace it if necessary.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit: 11.055 mm
Dial gauge

Measure the outer diameter of the piston.

Replace the piston if its measured value
exceeds allowable limit. Piston
Allowable limit: 10.945 mm

Micrometer

Assembly
circlip
CAUTION rubber boot
It is necessary to replace the whole set piston brake lamp
comprising piston, spring, piston cup, switch
and circlip. rubber spring
Make sure there is no dust on all washer
components before assembling.
master
cylinder
Apply clean brake fluid to the piston cup, and
then install the cup onto the piston.
Install the larger end of the spring onto the
master cylinder.
The master cup’s cavity should be face inside
of master cylinder when installing the master
cup.
Install the circlip.
CAUTION
Never install cup lip in the opposite
direction.
Make sure the circlip is seated
securely in the groove.

Install the rubber pad into groove properly.

13-9
13. BRAKE SYM

INSTALLATION master cylinder

mounting
Place the master cylinder onto handlebar, seat
brake
and install the split ring and bolts. The
hose
“UP” mark on the split ring should face
upward.
Align the split ring on the master cylinder
seat with the alignment point on the
handlebar.
Tighten the upper bolt of the seat to bolts x 2
specified torque value, and then tighten split ring
lower bolt to the same specified torque
“UP” mark
value.

sealing washer

Install the brake lever, and connect leads to

hose bolt
brake lamp switch.
Connect brake hoses with 2 new washes.
Tighten the brake hose bolt to the specified
torque value.
Torque value: 3.5 kgf-m
Make sure the hose is installed correctly.
CAUTION brake hose
Improper routing may damage leads, hoses
or pipes.

CAUTION
Kink of brake leads, hose or pipe may
reduce brake performance.

Add specified brake fluid and bleed the

system and conduct the air-bleeding job for
the system.

13-10
SYM 13. BRAKE

DRUM BRAKE-DRUM
Brake Drum
Removal
Use a vacuum cleaner and other suitable
tools to clean the brake parts to minimize
the hazard caused by the dust.
Caution
•Inhaling dust may cause respiration
system disorder even cancer. Never
use an air hose or a dry brush as to
clean the brake parts. Front brake drum
•Grease on brake pad will reduce
braking efficiency.
Remove wheel. Remove brake drum from
wheel hub.
Inspection
Check the brake drum for wear and damage,
replace wheel hub if necessary
Measure the ID of hub at several points and
record the largest value.
Service limit : 131.0 mm
Caution
•Remove the rust by using #120 sand Rear brake drum
paper.
•An inside micrometer must be used Front
when measuring ID of brake drum
because the brake drum has a friction
back plate.

BRAKE PAD
Inspection Brake
Measure the thickness of the brake pad at pad
three points (both ends and center).
If the thickness is less than specified, or if it is
contaminated by oil or grease, replace as a
set.
Service limit : Front 2.0 mm
Rear 2.0mm Brake pad

13-11
13. BRAKE SYM
Removal
front brake cam
Caution
Brake pads must be replaced as a set.
brake spring
Remove brake shoes from the brake panel by
pulling out the brake pads with two hands.

Installation
Apply a thin coat of grease to the brake cam 後 anchor pin
and the anchor pin. brake shoes
Hook the brake spring onto the brake cam.
Pull out the brake pads and install them onto
the brake panel. Wipe off the excessive rear brake cam
grease from the brake cam and the anchor pin
after installation.
Slightly grind the brake pad surfaces with
sand-paper to clean the surfaces. anchor
pin
Caution
Braking efficiency will be reduced if
brake pad is contaminated by oil or
grease. brake spring brake shoes

BRAKE PANEL
Removal Front Brake cam Brake arm
Remove the brake arm bolt and then
remove the brake arm, wear indicator,
brake return spring and brake cam as well
as the oil seal from the brake panel.

Return
spring
Wear indicator
Bolt

Rear Wear indicator

Return spring

13-12
SYM 13. BRAKE

Installation Front Return spring

FRONT BRAKE PANEL Wear
Apply a thin cost of grease onto the brake indicator
cam shaft. Oil seal
Install the brake cam.
Apply a thin cost of grease onto the oil seal Brake cam
lip and then install the oil seal onto the
brake cam shaft. Finally, install it on the
brake panel.
Align the end-part of the brake return spring
with the hole of brake panel. Brake arm
Align both the inner gear of wear indicator
and the mark on the brake arm with the
Rear Wear indicator
indent gear of brake cam, and then install it.
Tighten the bolts and nuts to specified
torque.
Torque: 0.8~1.2 kgf-m

REAR BRAKE PANEL

Apply a thin cost of grease between the oil
seals on the brake cam shaft.
Install the brake cam.
Align the mark on the brake arm with the
inner gear of the brake cam. Return spring
Brake arm
Tighten the bolts and nuts to specified
torque.
Hook on the return spring.
Torque: 0.8~1.2 kgf-m

13-13