13 BRAKING SYSTEM
REAR MASTER CYLINDER
Removal
1.
Remove the seat and rear panels, and disconnect
the batte
ry
negative (black) lead first.
CAUTION: To prevent body damage, do
not spill brake fluid onto any area of the
bodywork or wheels.
2.
Drain the fluid from the master cylinder by
bleeding the system at the rear caliper until all
fluid has been expelled.
3.
Remove the clip and washer from the clevis pin at
the lower end of the brake pushrod . Remove the
clevis pin.
4.
Disconnect from the master cylinder:
•
the rear brake hose (noting orientation),
•
the reservoir hose.
5.
Remove the screws securing the master cylinder
and heel guard to the frame to release the master
cylinder.
NOTE:
•
During removal of the master cylinder, note the
position of the brake light switch bracket and
spacing washer between the cylinder and
frame. Ensure both parts are refi
tt
ed in the
same positions.
Disassembly
1.
Remove the boot from the cylinder and pushrod.
2.
Remove the circlip retaining the pushrod to the
cylinder.
3.
Remove the pushrod and piston set from the
master cylinder bore noting the relative position of
the seals and piston components.
Inspection
1.
Visually inspect the master cylinder bore for wear,
scratches or corrosion. Replace as necessary.
2.
Check the piston and cylinder bore for damage,
wear or deterioration. Replace as necessary.
Always renew the piston seals if the cylinder has
been dismantled.
3.
Examine the pushrod for bends and damage.
Replace as necessary.
Assembly
WARNING: Never use mineral based
grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
A dangerous riding condition leading to an
accident could result if this warning is ignored.
1.
Clean the master cylinder bore, piston and seals,
with new brake fluid.
2.
Ensure all ports are clear of obstruction.
A
WARNING: Ensure that the piston and
piston seal are fitted facing the same way
as noted during removal. A dangerous riding
condition leading to an accident could result from
incorrect assembly of the master cylinder.
3.
Install the spring and piston set together.
4.
Apply a small amount of brake grease to the
pushrod.
5.
Install the pushrod in the master cylinder and
retain with a new circlip. Refit the
boot.
K,
5 ---^
1
2
4
,^
galb
1.
Clip
2.
Clevis pin
3.
Reservoir hose
4.
Dust boot
5.
Circlip
6.
Piston set
13.20
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