7.21
FINAL DRIVE/BRAKES
7
9. Repeat steps 7 and 8 until you see new brake fluid coming
from the caliper bleeder fitting or if you are bleeding the
air, repeat this step until you see only fluid coming out. This
may take several intervals.
10. Torque the bleeder screw to 8-11 ft-lb (11-15 N-m).
11. When adding fluid, add DOT 4 brake fluid to 1/4-5/16" (.6-
.8 cm) from the reservoir top.
12. Install cover and diaphragm assembly.
13. Tighten the cover screws to 16-20 in-lb (1.8-2.3 N-m).
14. Field test machine before putting into service. Check for
proper braking action and lever reserve. Lever reserve is
when the lever is firmly applied, the lever reserve should
be no less than 1/2" (1.3 cm) from the handlebar.
15. Verify that the sight glass indicates a full reservoir.
16. Check brake system for any fluid leaks.
Brake Line Replacement
Follow these steps if the brake line is to be replaced.
1. If needed bleed the brake system by attaching a clear hose
to the caliper bleed fitting.
2. Attach the other end to a Mity Vac or similar vacuum tool.
3. Bleed the system of brake fluid.
4. Note the orientation of the brake line. The brake line will
need to be replaced in the same orientation.
5. Remove the brake line from the caliper. Cap or cover the
end to catch any brake fluid that may still be in the line.
6. Loosen the brake line from the master cylinder 1/4 to 1/2
turn.
7. Remove the 4 screws that hold the master cylinder to the
handlebar. This will separate the master cylinder from the
switch pack.
8. Unplug the brake light switch harness from the master
cylinder.
9. Remove the brake line from the master cylinder.
10. Install new brake line on caliper and orientate it as noted in
step 4.
= T
Bleeder Screw: 8-11 ft-lb (11-15 N-m)
= T
Cover Screws: 16-20 in-lb (1.8-2.3 N-m)
144-192 in-lb (16-22\N-m)
brake light switch
168-216in-lb (18.9-24.4 N-m)
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