BRAKES 12-17

Master Cylinder

Front Master Cylinder Removal

•Remove the reservoir mounting bolt and nut [A].

•Unscrew the banjo bolt [A] and remove the brake hose from the master cylinder (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

•Unscrew the clamp bolts [B], and take off the master cylinder as an assembly with the reservoir, brake lever, and front brake light switch installed.

•Disconnect the front brake light switch connector [C].

CAUTION

Immediately wash away any brake fluid that spills.

•Remove:

Brake Lever Pivot Bolt [A] and Nut [B] Brake Lever [C]

Clamp [D] (Slide Out) Brake Hose [E]

Front Brake Light Switch [F]

Front Master Cylinder Installation

•Apply silicone grease to the sliding surface of the brake lever pivot bolt.

•Tighten:

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9 in·lb)

Brake Lever Pivot Bolt Nut: 5.9 N·m (0.60 kgf·m, 52 in·lb)

•Install the front brake light switch.

•Tighten:

Torque - Front Brake Light Switch Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)

12-18 BRAKES

Master Cylinder

•Install the master cylinder clamp [A] so that the arrow mark [B] faces upward.

•Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar.

•Tighten the upper clamp bolt first, and then the lower clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

•Connect the front brake light switch connector [A] as shown in the figure.

Left Side View [B] Front [C]

•Replace the washers that are on each side of the hose fitting with new ones.

•Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 in·lb)

•Bleed the brake line (see Brake Line Bleeding).

•Check the brake for good braking power, no brake drag, and no fluid leakage.

Rear Master Cylinder Removal

•Unscrew the brake hose banjo bolt [A] and remove the brake hose (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

•Remove:

Rear Master Cylinder Mounting Bolts [B] Foot Guard [C]

Front Footpeg Bracket Bolts [D]

BRAKES 12-19

Master Cylinder

•Remove: Cotter Pin [A] Joint Pin [B]

•Slide the reservoir hose lower end clamp [A].

•Pull off the reservoir hose lower end [B], and drain the brake fluid into a container.

Rear Master Cylinder Installation

•Replace the cotter pin [A] with a new one.

•Insert the cotter pin and bend the pin ends [B].

•Replace the washers that are on each side of hose fitting with new ones.

•Tighten:

Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

NOTE

○Depress the brake pedal [A] and then align the holes of the master cylinder [B].

○After installation, check that the rear brake light switch spring is hooked on the return spring.

•Bleed the brake line (see Brake Line Bleeding).

•Check the brake for good braking power, no brake drag, and no fluid leakage.

Front Master Cylinder Disassembly

•Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

12-20 BRAKES

Master Cylinder

Rear Master Cylinder Disassembly

•Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Master Cylinder Assembly

•Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Master Cylinder Inspection (Visual Inspection)

•Remove the master cylinders (see Front/Rear Master Cylinder Removal).

•Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter).

•Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].

If a master cylinder or piston shows any damage, replace them.

•Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups.

If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.

•Check the dust covers [E] for damage. If they are damaged, replace them.

•Check the piston return springs [F] for any damage. If the springs are damaged, replace them.

•Check that relief port [G] and supply port [H] are not plugged.

If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

Front Master Cylinder [I]

Rear Master Cylinder [J]