128
4. Inspect the banjo-fitting for cracks and deterioration
and the condition of the fittings (threaded and com-
pression).
INSTALLING
1. Position the brake housing on the handlebar. Secure
with clamp screws; then tighten securely.
XR090A
2. Using two new crush washers, connect the banjo-fit-
ting to the master cylinder; then secure with the
banjo-fitting bolt. Tighten to 20 ft-lb (27.2 N-m).
XR092A
3. Install the brake lever, pivot pin, and snap ring.
4. Bleed the brake system (see Periodic Mainte-
nance/Tune-up).
Hydraulic Brake Caliper
REMOVING/DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.
2. Drain the brake fluid from the caliper, hose, and mas-
ter cylinder through the bleed screw by pumping the
brake lever/pedal.
NOTE: Whenever brake components are removed,
disassembled, or repaired where brake fluid is
exposed to air, drain all fluid and replace with new
DOT 4 brake fluid from an unopened container.
Brake fluid readily absorbs moisture from the air sig-
nificantly lowering the boiling point. This increases
the chance of vapor lock reducing braking power and
increasing stopping distance.
3. Remove the brake hose from the caliper and close
the bleed screw; then remove the caliper.
4. Compress the caliper holder against the caliper
(opposite the O-ring side) and remove the outer
brake pad; then remove the inner brake pad.
NOTE: If brake pads are to be returned to service,
do not allow brake fluid to contaminate them.
PR237A
PR238
5. Remove the caliper holder from the caliper and dis-
card the O-ring.
! WARNING
It is recommended that only authorized ATV dealers
perform hydraulic brake service. Failure to properly
repair brake systems can result in loss of control caus-
ing severe injury or death.
! WARNING
Make sure the vehicle is solidly supported on the sup-
port stand to avoid injury.
! WARNING
Never let brake fluid contact the eyes. Damage to the
eyes will occur. Always wear appropriate protective
safety goggles and latex gloves when handling brake
fluid.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the vehicle and do not reuse brake
fluid.
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