6.18
BODY AND STEERING
Foot Brake Master Cylinder Removal /
Installation
1. If necessary, remove the rear brake lines (B) from the
master cylinder (C). Use a suitable container to catch the
brake fluid. Dispose of brake fluid properly.
2. Remove the two bolts that secure the rear master cylinder
to the brake mount plate. Replace parts as needed.
3. To install the rear brake master cylinder, mount the master
cylinder to the mount plate and torque bolts to 8 ft.lbs. (11
Nm).
4. Reinstall the brake line and torque the banjo bolt (with
new copper washers installed) to 22 ft.lbs. (30 Nm).
Torque the flared fitting (if removed) to 12-15 ft.lbs. (16-
21) Nm.
5. Bleed the master cylinder following the procedure
outlined in the brake bleeding section of this manual.
TROUBLESHOOTING
BRAKE SQUEAL
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn caliper
POOR BRAKE PERFORMANCE
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch
LEVER VIBRATION
• Disc damaged
• Disc warp (runout or thickness variance exceeds
service limit)
CALIPER OVERHEATS (BRAKES DRAG)
• Compensating port plugged
• Foot brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
BRAKES LOCK
• Alignment of caliper to disc
• Compensating port plugged
• Parking brake left on
A
B
C
D
F
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