FRONT MASTER CYLINDER
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SEALING WASHERS |
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OIL BOLT |
Drain the front brake hydraulic system (page 16-6).
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Remove the brake hose oi and brake hose eyelet. |
bolt, sealing washers
When removing the brake hose oil bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out.
Remove the bolts, holder and master cylinder assembly.
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MASTER CYLINDER
HOLDER BOLTS |
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DUST COVER PIVOT BOLT/NUT
BRAKE LEVER |
Remove the dust cover.
Remove the pivot bolt/nut and brake lever assembly.
Remove the boot.
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BOOT |
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Remove the snap ring from the master cylinder body using the special tool as shown.
TOOL:
Snap ring pliers 07914-SA50001
Remove the washer, master piston and spring.
WASHER
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SPRING |
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PISTON |
Clean the inside of the cylinder and reservoir with brake fluid.
Check the piston boot, primary cup and secondary cup for fatigue or damage.
Check the master cylinder and piston for abnormal scratches.
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Measure the master cylinder I. D. SERVICE LIMIT: 11.050 mm (0.4350 in)
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Measure the master piston O. D. SERVICE LIMIT: 10.840 mm (0.4268 in)
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Replace the piston, cups, spring, snap ring and boot as a set; do not substitute individual parts. |
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PISTON |
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WASHER |
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Dip the piston and master cylinder I. D. in brake fluid.
Install the spring to the piston.
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When installing the cups, do not allow the lips to turn inside out |
Install the piston assembly into the master cylinder.
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Install the snap ring using the special tool. TOOL: Snap ring pliers 07914-SA50001 Apply silicone grease to the inside of the boot. Install the boot to the master cylinder. |
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Install the brake lever. Apply silicone grease to the pivot bolt sliding surface. Install and tighten the pivot bolt to the specified torque. TORQUE: 1.0 N m (0.1 kgf m, 0.7 lbf-ft) Tighten the pivot nut to the specified torque. TORQUE: 5.9 N-m (0.6 kgf m, 4.4 lbf-ft) Install the dust cover. |
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INSTALLATION Place the master cylinder assembly on the handlebar. Align the end of the master cylinder with the paint mark on the handlebar. Install the master cylinder holder with the "UP" mark facing up. Tighten the upper bolt first, then the lower bolt to the specified torque. TORQUE: 9.9 N m (1.0 kgf m, 7.3 lbf-ft) |
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SNAP RING |
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Be certain the snap ring is firmly seated in the groove. |
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BOOT |
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DUST COVER PIVOT BOLT/ NUT
BRAKE LEVER |
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MASTER CYLINDER PAINT MARK |
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HOLDER |
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BOLTS |
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Align the brake hose eyelet between the stoppers. Install the brake hose eyelet with the oil bolt and new sealing washers.
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BRAKE HOSE |
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OIL BOLT |
Tighten the brake hose oil bolt to the specified torque.
TORQUE: 34 N m (3.5 kgf m, 25 Ibf ft)
Fill and bleed the front brake hydraulic system (page 16-7).
SEALING WASHERS
