2.12FRONT BRAKE MASTER CYLINDER
GENERAL
Do not use parts from single caliper repair kits (9/16 inch
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
See Figure 2-62. Master cylinders designed for single disc (one
caliper) operation have a 9/16 in. (14.3 mm) bore. The bore
size is stamped on the master cylinder assembly inboard of
the handlebar clamp bracket.
1. Single disc master cylinder
2. Bore stamp size
Figure 2-62. Bore Size
REMOVAL AND DISASSEMBLY
1. Open bleeder nipple cap on front brake caliper. Install end
of a length of clear plastic tubing over caliper bleeder
valve, while placing free end in a suitable container. Open
bleeder valve about 1/2-turn. Pump brake hand lever to
drain brake fluid. Close bleeder valve.
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)
2. Remove bolt and two steel/rubber washers to disconnect
fitting of hydraulic brake line from master cylinder. Discard
washers.
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
2-32 2008 Dyna Service: Chassis
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