11.14.03.04

.04 Brakes.

Procedures: Reject Vehicle If:
A. (1) At a speed of 20 mph on a smooth level, dry surface which is free from loose material, the brakes are required to stop the motorcycle within 30 feet.
   (2) If vehicle is equipped with both front and rear brakes, determine if there is adequate braking action at both wheels.
A. (1) The motorcycle fails to stop within 30 feet.
   (2) There is inadequate brake action on either wheel.
   (3) There is obvious vibration, wobble, or bounce caused by warped brake rotor or brake drum out of round.
B. Mechanical Brake System. Inspect linkage, cables, pivots, and bearings for high friction, wear, and broken or missing parts. Motorcycles manufactured after January 1, 1974, shall have brakes on all wheels.
C. Condition of Mechanical Components in Hydraulic or Mechanical Systems.
   (1) Inspect for worn pins and missing or defective cotter pins.
B. (1) Brake adjustment changes under any steering or loading conditions.
   (2) Cotter pins are missing.
   (3) Pins or clevises worn more than 25 percent of the original diameter.
   (4) The cam operating lever has been repositioned on the shaft as a means of avoiding replacement of worn cam, shoes, or lining.
   (2) Inspect for broken or missing springs and worn cables, clevises, couplings, rods, and anchor pins.
   (3) Inspect for frozen, rusted, inoperative connections, missing spring clips, and defective grease retainers.
   (4) Inspect pedal shaft and bearings for high friction, wear, and misalignment.
   (5) Any cables are frayed (two or more broken strands).
   (6) Any brake adjustment mechanism which will not maintain an adjusted position or is adjusted to its maximum extent.
   (7) Front brake cable is routed so as to be pinched between fork and frame.
   (5) Inspect for restriction of shoe movement at backing plate and for bind between brake shoes and anchor pins.
   (6) Inspect actuating cam for excessive wear, camshaft for looseness in backing plate bushing and determine that springs are of sufficient strength to return and hold shoes against cam.
   (8) There is any roughness, binding, or jamming in levers or pedals.
   (9) Less than 1/3 travel remains in hand or foot brake when brakes are applied.
   (10) Modifications make the pedal inaccessible for adequate leverage or operation.
   (11) Manufactured after January 1, 1974, and not equipped with brakes on all wheels.
D. Hydraulic System. Motorcycles manufactured after January 1, 1974, shall have brakes on all wheels. C. (1) Mechanical parts are missing, broken, or badly worn.
   (1) Visually inspect condition of hydraulic system.    (2) There is excessive friction in pedal and linkage or in brake components.
   (2) Inspect hydraulic hoses and tubes for leaks, cracks, chafing, flattened or restricted sections, and improper support.    (3) Pedal or levers are improperly positioned or misaligned.
   (3) Inspect master cylinder for leakage and fluid level.    (4) Grease seals are defective, dripping, or slinging grease.
   (4) Inspect master cylinder push rod for improper adjustment.
   (5) Inspect wheel cylinders or hydraulic brake actuating systems.
D. (1) Hoses or tubing leaks or they are cracked, chafed, flattened, restricted, or are improperly fastened.
   (2) Master cylinder leaks or the reservoir is less than 1/2 full.
   (3) There is any leakage in the braking system.
   (4) The push rod is improperly adjusted.
   (5) Wheel cylinder or caliper leaks or fails to function.
   (6) Manufactured after January 1, 1974, and is not equipped with brakes on all wheels.

At least one rear wheel and drum assembly shall be removed (for inspection of linings on vehicles equipped with drum brakes) from a three-wheeled multipurpose vehicle for lining, drum, and component inspection. Removal of a wheel on any other motorcycle shall be required only if any malfunction of braking is discovered during a road test. 1974 and newer motorcycles have a means of inspecting brake lining thickness without removing a wheel.

Procedures: Reject Vehicle If:
E. Condition of Linings and Pads.
   (1) Bonded—Measure the lining thickness at the thinnest point.
E. (1) Brake lining wear reference mark indicates unsafe or replacement.
   (2) Riveted—Measure lining thickness at thinnest point.    (2) Thinnest point of bonded lining is less than 2/32 inch.
   (3) Wire-backed—Inspect for wire showing on the friction surface of the lining.    (3) Any rivets are loose or missing. Lining is worn less than 2/32 inch above any rivet head.
   (4) All Linings or Pads—Inspect for broken or cracked linings, and parts of linings not firmly attached to shoe. Also inspect for contamination and excessively uneven lining or pad wear. Circumferential head cracks on bonded linings are not reason for rejection if the lining is securely attached to the shoe.    (4) Wire backing is visible on the friction surface.
   (5) Lining is broken, cracked, or not firmly and completely attached to shoe.
      (a) Friction surface is contaminated with brake fluid, oil, or grease.
      (b) Lining wear is extremely uneven.
F. Brake Drums.
   (1) Inspect condition of the drum friction surface for substantial cracks extending to the open edge of the drum. Short hairline heat cracks should not be considered.
F. (1) There is any substantial crack on the friction surface extending to open edge. Excessive wear (0.060 maximum) over original diameter or in excess of diameter embossed on drum. Grooving exists.
   (2) Inspect for cracks on the outside of the drum.    (2) There is any external crack.
   (3) Inspect for mechanical damage.    (3) There is evidence of mechanical damage other than wear.
   (4) Inspect for contaminated friction surface.    (4) Friction surface is contaminated with oil, grease, or brake fluid.
G. Brake Discs.
   (1) Inspect for substantial cracks extending to edge of disc.
G. (1) There is any substantial crack extending to the edge. Worn beyond manufacturer's tolerances for replacement.
   (2) Inspect for mechanical damage.    (2) There is evidence of mechanical damage other than wear.
   (3) Inspect for contaminated friction surface.    (3) Friction surface is contaminated with oil, grease, or brake fluid.