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Fuoco - 500 302 314

The document provides detailed instructions for the removal, overhaul, and refitting of the braking system components for the Fuoco 500 i.e., including rear and front brake calipers, brake discs, and pads. It emphasizes the importance of checking for wear limits, ensuring proper torque during reassembly, and replacing seals and gaskets whenever serviced. Additionally, it outlines the procedure for bleeding the brake system and maintaining the parking brake mechanism.

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© All Rights Reserved
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7 views13 pages

Fuoco - 500 302 314

The document provides detailed instructions for the removal, overhaul, and refitting of the braking system components for the Fuoco 500 i.e., including rear and front brake calipers, brake discs, and pads. It emphasizes the importance of checking for wear limits, ensuring proper torque during reassembly, and replacing seals and gaskets whenever serviced. Additionally, it outlines the procedure for bleeding the brake system and maintaining the parking brake mechanism.

Uploaded by

suzukijwy
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Braking system Fuoco 500 i.e.

This section è is devoted to the description of the brake system components.

Rear brake calliper

Removal
- Remove the rear wheel.
- Undo the screws connecting the air filter to the
crankcase so that the wrenches can be inserted.
- Undo the two fixing screws and remove the cal-
liper.
N.B.
IF IT IS NECESSARY TO REPLACE OR SERV-
ICE THE BRAKE CALLIPER, BEFORE REMOV-
ING THE FITTINGS FIXING THE CALLIPER TO
THE SUPPORT BRACKET, FIRST LOOSEN
THE OIL HOSE FITTING AFTER HAVING EMP-
TIED THE SYSTEM OF THE CIRCUIT BEING
EXAMINED.

Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of com-
pressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the cal-
liper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.

BRAK SYS - 2

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Fuoco 500 i.e. Braking system

Refitting
1) insert the pistons (6) and the sealing rings (7) in
the body;
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corre-
sponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction prin-
ciple to obtain the thrust for both pads.
The body and the reaction plate body work inte-
grally and can move axially with respect of the
fixed plate that is integral to the strut.
The pistons, forced by pressure to push the pad to
the disk, cause the reaction plate to push in turn
the other pad towards the disc.
The brake pad lock spring
1. Pad fixing screws
2. Reaction plate fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubbers
9. Brake pad check spring
10. Pads
CAUTION
ALL THE SEALS AND GASKETS MUST BE RE-
PLACED EVERY TIME THE CALLIPER IS
SERVICED.
Locking torques (N*m)

BRAK SYS - 3

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Braking system Fuoco 500 i.e.

Brake fluid hose-calliper fitting 20 ÷ 25 Pad fas-


tening pin 20 ÷ 25

Refitting
- To fit the rear brake calliper, follow the removal steps but in reverse order; be careful to tighten the
screws to the prescribed torque.

Locking torques (N*m)


Screw tightening calliper to the support 20 ÷ 25

Front brake calliper

Removal
- The operations described refer to only one cal-
liper but apply to both.
- Remove the wheel.
- Undo the two fixing screws to the plate and re-
move the calliper.

Overhaul
- Remove the rear brake calliper.
- Suitably hold the brake calliper in a clamp
- Remove the two calliper coupling screws as
shown in the photo
- Remove the two pistons from the calliper body
with the aid of short blasts of compressed air
through the brake fluid holes
- Remove the dust ring and the O-ring of each half
calliper.
- Remove the O-rings in the half calliper.
N.B.
WHEN REMOVING THE O-RINGS, BE CARE-
FUL NOT TO SCRATCH THE HALF CALLIPER
SEATS

BRAK SYS - 4

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Fuoco 500 i.e. Braking system

- Check that the pistons and their seats show no


scratches.
- Wash and blow all the components carefully
- Fit the O-rings and new dust guards
- Refit the pistons in their seats being careful to
lubricate with brake fluid
- Re-couple the half callipers and lock the two
screws at the specified torque

Locking torques (N*m)


Calliper coupling screw 22 ÷ 27

Refitting

Rear brake disc

BRAK SYS - 5

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Braking system Fuoco 500 i.e.

Removal
- Remove the rear wheel.
- Loosen the nuts fixing the safety washers.
- Undo the two screws fixing the plate supporting
the calliper to the frame.

- Remove the calliper supporting clamp.

- Remove the brake disc

Refitting
- To fit the rear brake disc, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque using threadlock.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)


Rear disc screws 5 - 6.5 Nm

BRAK SYS - 6

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Fuoco 500 i.e. Braking system

Disc Inspection
Checking the disc is important; it must be perfectly
clean, with no sign of rust, oil or grease or other
dirt and must not show signs of deep scoring.

Characteristic
New rear disc thickness
5 mm
Disc thickness at wear limit (rear)
3.5 mm

- Remove the wheel and check using the appro-


priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN
THE DISC AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm

Front brake disc

Removal
- The operations described refer to only one disc
but apply to both.
- Remove the wheel.
- Remove the brake calliper.
- Remove the cotter pin and remove the cap.

BRAK SYS - 7

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Braking system Fuoco 500 i.e.

- Unscrew the fixing nut.

- Remove the wheel hub.

- Unscrew the six bolts securing the disc to the


wheel hub.
- Remove the disc.

Refitting
- To fit the front brake disc, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque using threadlock.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)


Front disc screws 5 ÷ 6 Nm

Disc Inspection
Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt
and must not show signs of deep scoring.

BRAK SYS - 8

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Fuoco 500 i.e. Braking system

Characteristic
Thickness of a new front disc
4.0 mm
Disc thickness at wear limit (front)
3.5 mm

- Remove the wheel and check using the appro-


priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN
THE DISC AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm

Front brake pads

Removal
- Remove the brake calliper.
- Remove the Benzing snap ring of the pad pin.

- Slide off the pin paying attention to collect the


retaining spring of the pads.

BRAK SYS - 9

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Braking system Fuoco 500 i.e.

- Remove the pads.

Characteristic
Minimum value
1.5 mm

Refitting
- Follow the removal steps but in reverse order; check that the Benzing snap ring of the pads is in good
conditions.

Rear brake pads

Removal
Proceed as follows:
- Remove the rear brake calliper
- Remove the two pins holding the brake pads.
- Remove the pads, paying attention to the pad re-
taining spring.
- Check the thickness of the pads.
If the thickness is less than the minimum value,
replace the pads with new pads.

Characteristic
Minimum value
1.5 mm

Refitting
- To fit the rear brake pads, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque.

Locking torques (N*m)


Screws tightening the pad fixing pin 20 ÷ 25 Nm

Fill

BRAK SYS - 10

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Fuoco 500 i.e. Braking system

Rear - combined
Proceed as follows:
- Position the vehicle on a flat surface and on the
stand
- Loosen the two screws shown in the figure and
open the front brake fluid reservoir.

- Through the bleed screw on the brake calliper,


bleed the system using a hose of adequate diam-
eter.
- Collect the used fluid in a container.

- Pump on the brake lever to completely drain the system of all used fluid.
- Tighten the bleed valve.
- Refill the brake system tank up to the maximum level with the prescribed fluid.
- Attach the tube of the special tool to the bleed fitting.
- Actuate the tool at the bleed fitting, at the same time constantly topping up the brake system tank to
prevent air being drawn into the system, until no more air escapes at the bleed fitting. The operation is
finished when only brake fluid comes out of the bleed screw.
- Close the bleed screw and tighten to the prescribed torque.
- Close the brake system tank.
N.B.
IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-
TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUT
THE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND
ON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE
DISC.
Specific tooling
020329Y Mity-Vac vacuum operated pump

Locking torques (N*m)


Oil bleed screw 12 - 16

BRAK SYS - 11

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Braking system Fuoco 500 i.e.

Front
- The operations described refer to only one cal-
liper but are valid and must be observed for both.
- Remove the rubber hood from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.

- With the right-hand brake lever, load the system and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen the bleed screw to permit the air in the system to
escape. Then tighten the bleed screw.
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber hood over the bleed screw.
- Top up the brake fluid to the right level in the tank.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKE SYSTEM
If necessary, bleeding can be done using a special vacuum pump

Specific tooling
020329Y Mity-Vac vacuum operated pump

Locking torques (N*m)


Oil bleed screw 8÷12

Brake pipes
Unscrew the braking splitter screw.
Disconnect the brake pipes removing the two met-
allic straps indicated in the figure.
Remove the brake oil tube fitting from the rigid pipe
inside the front suspension arm and loosen the
hydraulic joint fixing nut of the suspension locking
to release the brake pipes.

BRAK SYS - 12

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Fuoco 500 i.e. Braking system

Remove front Shield.


Remove front wheel and mudguard.
Disconnect the brake pipes from the calliper and
drain the brake fluid.
Then, remove the plastic and metallic straps.
Unscrew the brake pump pipes as indicated in the
figure.

Parking brake
Remove the rear wheel.
Loosen the transmission set screw and release the
cable from the calliper.

BRAK SYS - 13

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Braking system Fuoco 500 i.e.

Remove the two fixing screws of the mechanic


calliper and remove the calliper. To check calliper
components, refer to the chapter on the tilt locking
calliper.
When refitting, secure to the specified torque.

Locking torques (N*m)


Screw tightening calliper to the support 20 ÷ 25

After removing the shield back plate, remove the


engaging cable for the safety mechanism remov-
ing it from its fitting.
Remove the 4 screws shown in the figure.
When refitting, pay attention to insert the metallic
cable peg in the fitting marked «A» as indicated in
the enlarged photograph.

Remove the electric connection from the engaged


parking brake warning light switch.

Remove the parking brake cable from the lever by


operating the set screw indicated in the photo-
graph.

BRAK SYS - 14

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Common questions

Powered by AI

When replacing brake pads, one must first remove the calliper and take out the fixing pins while noting the condition of the retaining springs . The pad thickness should be checked; if it is below 1.5 mm, the pads should be replaced with new ones. During refitting, ensure all components are secured to the prescribed torque (20 ÷ 25 Nm). It's essential to verify the condition of the Benzing snap ring and retain all components in the correct order to ensure proper brake function . Proper replacement and installation ensure the pads make full contact with the disc for effective braking.

During brake component servicing, it is essential to avoid scratching or damaging component seats, particularly when handling O-rings and pistons . Ensuring that brake fluid does not contact bodywork, brake pads, or disc surfaces is crucial to prevent potential damage or decreases in brake performance. Additionally, all seals and gaskets should be replaced whenever the calliper is serviced to avoid leaks . Proper cleaning, lubrication, and torque application are also essential to maintain system integrity and prevent malfunctions .

In a floating-type brake calliper, the braking process utilizes the action and reaction principle. The pistons, when forced by pressure, push one pad towards the brake disc. This action causes the reaction plate body to move integrally with the calliper body axially, pushing the other pad towards the disc as well . This system allows both pads to engage the disc simultaneously, enhancing braking efficiency. The body and the reaction plate body do not move separately; instead, they work integrally, providing balanced force application on both sides of the disc .

To overhaul a rear brake calliper, the procedure involves several critical steps: removing the two male hexagonal screws to take out the pads, removing the reaction plate, and taking out the fixed plate from the guide. Compressed air is then used to expel the pistons from the floating body . During this process, it is essential to check that all components, especially seals and gaskets, are in good condition, as all seals and gaskets must be replaced every time the calliper is serviced to ensure no leaks or air intake, which could compromise the braking system's efficiency .

Brake disc thickness and axial run-out are critical factors in deciding replacement. If the disc thickness measures at or below the wear limit (3.5 mm), it indicates excessive wear, impacting the disc's ability to dissipate heat and handle stress, leading potentially to failure . Excessive axial run-out (beyond 0.1 mm) can cause vibrations, noise, and uneven pad wear, affecting braking performance and safety. Regular inspection ensures these parameters are within limits to maintain optimal braking efficiency and safety .

Brake disc inspection requires ensuring that discs are perfectly clean and free of rust, oil, grease, or deep scoring . The disc thickness must be checked, ensuring it remains above the wear limit (3.5 mm for both front and rear discs). Axial run-out must also be assessed and kept within 0.1 mm. If any of these parameters are outside specified tolerances, the disc must be cleaned thoroughly or replaced to avoid reduced braking efficiency or damage .

Threadlock compounds, such as Loctite 243, are used to prevent the loosening of screws due to vibration, ensuring that components remain securely fastened over time . Specified torque values ensure that screws are neither under-torqued, risking component loosening, nor over-torqued, which could damage threads or components. Adhering to these specifications is crucial for maintaining the integrity and safety of the brake system .

Bleeding a brake system involves removing the air trapped in the brake lines to ensure proper brake function. This is done by opening the bleed valve and pumping the brake lever to expel air and old fluid, then topping up with new fluid while ensuring no air re-enters the system. Using a vacuum-operated pump, like the Mity-Vac, can facilitate this by creating a vacuum that draws fluid through the system, reducing the chance of air entering . This procedure prevents brake sponginess and ensures consistent hydraulic pressure .

Refitting a brake calliper requires following removal steps in reverse order, ensuring screws are tightened to the specified torque (20 ÷ 25 Nm) to secure the calliper to its support . Precision is crucial as improperly torqued screws can result in the calliper loosening during operation, leading to reduced braking efficiency or failure. Accurate refitting ensures that brake components function correctly, maintaining alignment and optimal contact with the brake disc . Consistent application of these guidelines directly affects vehicle handling and safety in braking scenarios.

Replacing brake fluid is critical because it degrades and absorbs moisture over time, reducing its boiling point and overall efficiency. If brake fluid replacement is inadequately performed, moisture accumulation can lead to vapor lock and reduced braking performance under high temperatures. Furthermore, old fluid can corrode internal components, leading to leaks or failures. Proper replacement involves draining old fluid, ensuring no air remains in the system, and refilling with fresh fluid to maintain optimal system performance .

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