5.24
Final Drive/Brake System
Brake Line Replacement
Follow these steps if the brake line is to be replaced.
1. Drain the brake system by attaching a clear hose to
th
e caliper bleed fitting.
2. Attach the other end to a Mity Vac or similar vacuum
to
ol.
3. Bleed the system of brake fluid.
4. Note the orientation of the brake line. The brake line
w
ill need to be replaced in the same orientation.
Remove the brake line from the caliper assembly. Use
a shop towel to catch any remaining brake fluid in the
hose.
5. On Cyclone master cylinders, remove the banjo bolt,
wa
shers and fitting from reservoir.
6. On combined master cylinder, loosen the brake line
fr
om the master cylinder 1/4 to 1/2 turn.
7. Remove the 4 screws that hold the master cylinder to
the handlebar. This will s
eparate 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
no
ted in step 4.
11. Insert the new brake line and install into the master
c
ylinder. Torque the brake line to specification.
12. Tighten the brake line into the master cylinder in an
or
ientation so that the line does not have any sharp
bends when it is installed on the handlebar.
13. Route the brake light switch
in the harness correctly.
BRAKE SWITCH
BRAKE HOSE FITTING
COMBINED MASTER CYLINDER SHOWN
Brake Caliper Banjo Bolt:
240-264 in-lbs (27-30Nm)
Brake Line-to-Master Cylinder:
240-264 in-lbs (27-30Nm)
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