6.12
Final Drive and Brakes
escape. You will feel the lever release as you let the fluid
or air escape.
8. Pump the brake lever a few times and hold it again.
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.
Master Cylinder / Lever Service
1. To remove the brake lever, remove the E clip from the
lever pin.
2. Extract the pin from the housing, then remove the lever.
3. To remove the parking brake lever, the housing cover must
be removed. Once removed, carefully extract the spring
noting it its position inside the housing. Remove the
parking brake lever.
4. To remove the cartridge, completely drain the brake fluid
from the housing. Remove the brake and parking brake
levers.
5. Disconnect the brake hose from the cartridge. Carefully
pop the cartridge out of the housing.
6. To install the cartridge, lubricate the entire surface with
DOT 4 brake fluid.
7. Align the cartridge with the housing tabs, then firmly press
the cartridge back into the housing until the cartridge is
engaged with the tabs.
8. Refill and bleed the brakes system as outlined in this
chapter. See “Brake Fluid Replacement & Bleeding” on
page 6.11.
= T
Bleeder Screw: 8-11 ft-lb (11-15 N-m)
= T
Cover Screws: 16-20 in-lb (1.8-2.3 N-m)
COVER SCREWS
COVER
PARKING BRAKE LEVER
CARTRIDGE
BRAKE LEVER
LEVER PIN
E CLIP
SWITCH
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