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Replacing Rear Brake Pads (Touring)

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As with all maintenance, buying the service manual is highly recommended.
The socket for the pad pins is a 1/4", 12-point. Don't need to remove or even move the caliper, it can stay in place.

  1. Remove right side saddlebag.
  2. Loosen both pad pins, but do not remove.
  3. Remove two Phillips screws to release cover from rear master cylinder reservoir.
    1. NOTE
      As the pistons are pushed back into the caliper, fluid level may rise more than 1/4 inch (6.4 mm) and overflow the reservoir. Watch the fluid level as the pistons are retracted and remove fluid from the reservoir if necessary.
  4. Pry the inside pad back pushing the pistons into their bores as far as possible. Use a putty knife with a wide thin blade to avoid scoring or scratching the brake disc.
    1. NOTE
      Do not completely pull pad pins from caliper during the next step. Completely removing pad pins at this time will make assembly difficult.
  5. Once the pistons have been retracted, pull the pad pins part way out until the inside pad drops free. Note the orientation of the pad.
  6. Install newinside brake pad using the same orientation. Curved portion of pad must face rear of motorcycle.
  7. Install pad pins, but do not fully tighten.
  8. Pump rear brake pedal to move inside pistons out until they contact inside brake pad.
  9. Pry the outside pad back pushing the pistons into their bores. Use a putty knife with a wide thin blade to avoid scoring or scratching the brake disc.
  10. Verify that inside pad is captured between brake disc and pistons. Completely remove pad pins to free outside brake pad. Note the orientation of the pad.
  11. Install newoutside brake pad using the same orientation. Curved portion of pad must face rear of motorcycle. If the inside pad moved during the previous step, reinstall.
    1. NOTE
      Replacing one pad at a time keeps the anti-rattle spring in place. Remove both pads to remove or replace the spring.
  12. Inspect pad pins. See CLEANING AND INSPECTION, step 4.
  13. Install two pad pins and tighten to 180-200 in-lbs (20.3- 22.6 Nm).
  14. Pump rear brake pedal to move pistons out until they contact both brake pads. Verify piston location against pads.
  15. Verify that brake fluid level is 1/4 inch (6.4 mm) below top of reservoir with master cylinder in a level position. Add DOT 4 BRAKE FLUID, if necessary but make sure what DOT fluid is used in your bike.
  16. Install the master cylinder reservoir cover, but first verify that the cover gasket bellows is not extended or brake fluid will be ejected from the reservoir. Install two Phillips screws and alternately tighten to 6-8 in-lbs (0.7-0.9 Nm).
  17. Install master cylinder reservoir cover. Install two Phillips screws to fasten cover to reservoir and tighten to 6-8 inlbs (0.7-0.9 Nm).
  18. Install right side saddlebag. See Section 2.26 SADDLEBAG, INSTALLATION.
  19. Test operation of brake lamp with the rear brake applied and the Ignition/Light Key Switch turned to IGNITION.
  20. Test ride the motorcycle.
 
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