7. Remove and discard retaining ring (7) from bore of cart-
ridge body and remove push rod and washer (8).
NOTE
Do not disassemble cartridge body (11). The cartridge body
contains the piston and associated components. These parts
are not sold; therefore, replace the cartridge body if piston seal
leakage is evident.
CLEANING AND INSPECTION
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1. Clean exterior of master cylinder/reservoir with a clean,
nonflammable solvent. Lubricate all internal parts with
lubricant provided in kit.
2. See Figure 2-74. Inspect reservoir bore (12) for scratches.
Replace if scratches are present.
3. Check boot (3) for tears and replace if any exist.
4. Inspect threads on cartridge body (11), push rod (9) and
banjo bolt (19). Replace any part with damaged threads.
Inspect spring for cracks or broken coils - replace if any
exist.
5. Carefully remove large O-rings (10) from cartridge body.
Do not scratch O-ring grooves. Clean grooves with soft
cotton cloth moistened with alcohol. Inspect grooves for
scratches and dirt. Remove dirt or replace cartridge body
if grooves are scratched.
ASSEMBLY
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)
1. See Figure 2-74. Lubricate O-rings (10) with D.O.T. 4
brake fluid and install in O-ring grooves on cartridge body
(11).
2. Lubricate bore of master cylinder/reservoir (12) with D.O.T.
4 brake fluid.
3. Insert cartridge body into reservoir. Using hand-pressure
only, press cartridge body into adapter making sure notch
on cartridge body engages lug inside bore of the adapter.
4. Thread banjo bolt (19) into cartridge body and stand
master cylinder upright with banjo bolt resting on bench.
5. Place washer (8) on push rod (9).
6. Place a new retaining ring (7) on push rod. Insert ball-end
of push rod into piston. Push piston downward with push
rod until washer is properly seated in the cartridge bore.
7. Install the new retaining ring in groove inside cartridge
bore. Make certain retaining ring is fully seated in groove.
8. Release downward pressure on push rod and check that
push rod rotates freely.
9. Install retaining ring (6) in groove on cartridge body.
10. Install on push rod, spring (5), spring retaining washer (4)
(large cupped side toward spring), boot (3) with drain hole
down, and washer (2).
11. Press down on washer and install retaining ring (1) in push
rod groove.
12. Seat sealing lip of boot into groove on master cyl-
inder/reservoir adapter.
INSTALLATION
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)
1. See Figure 2-74. Guide threaded end of master cyl-
inder/reservoir (12) through hole in bracket (16). Make
sure the square body of the master cylinder/reservoir is
engaged in the square hole of the mounting bracket.
2. Install nut (17) and tighten to 30-40 ft-lbs (40.7-54.2 Nm).
3. Thread push rod (9) fully onto brake rod (22/23). Do not
tighten jam nut (21) at this time.
4. Lubricate new steel/rubber washers (18) with D.O.T. 4
BRAKE FLUID. Install brake line (20) using banjo bolt (19)
and new steel/rubber washers (18). Position brake line
and tighten banjo bolt to 21-25 ft-lbs (28.5-33.9 Nm).
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
When adjusting brake control rod, never allow more than
nine threads to be exposed between control rod and jam
nut. If more than nine threads are exposed, brake rod can
come apart resulting in loss of rear brake, which could
cause death or serious injury. (00306c)
5. Unscrew push rod from brake rod just enough to adjust
pedal height. When correct pedal height is obtained,
tighten jam nut. Make certain that no more than nine
threads are visible on brake rod.
2008 Dyna Service: Chassis 2-43
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