BRAKES,
WHEELS
AND
TIRES
Meanwhile, fluid returning from the wheel cylinder
lif"
the
check
valves (3)
away
from
Its
seat,
and
re-enters
the
cylinder.
When
the
piston
has fully
returned, a small breather port (8)
is
uncovered,
which allows a release
of
excess
fluid
to
the
reservoir
and
also
compensates
for
contraction
and expansion
of the flUid, due to changes In
temperature.
The
purpose
of
the
check valve (3)
is
to
prevent
the
re-entry
Into
the master cylinder of
fluid
pumped
into the line during the "bleeding" operation. thus
ensuring a
fresh
charge
of
fluid at
each
operation
of
the
brake.
SECTION
FII
FRONT
BRAKE
CYLINDER
Remova!
and
dismantling procedure
Is
as
follows.
First,
drain
the
system
of
fluid
(See
Section
F6).
Remove
the
rubber
hose
from
the
end
of
the
master
cylinder.
Remove
the
brake
lever
and push
rod
by
unscrewing
the
pivot
bolt.
Unscrew
the
four
retaining
screws
that
hold
the
right
switch
console, and
remove
the
master
cylinder
from the
handlebars.
Detach
the
reservoir
bowl
from
the
cylinder,
by remOVing
the
attachment
nut
from
the
inside (See
Item
12
Fig. F6).
Note
assembly
of
w~sher,
spacer, and 0 ring.
Remove
the
grub screw
that
locks
the
cylinder
In
position
in
the
switch
housing (See Fig. F6),
and
then
unscrew
the
cylinder.
Detach
the
rubber
boot
from
the
end
of
the
cylinder.
Using
the
push
rod
(1).
depress
the
piston
In
the
cylinder,
to
relieve
the
load
on
the
spring,
and
remove
the
circlip
(6).
Remove
the
piston
(2),
piston
washer
(7),
primary
seal
(5).
return
spring
(4),
and
check
valve
(3).
The
removal
of
the
primary
seal (5) may
be
simplified by
applying
gentle
air
pressure
to
the
pipe
connection
at
the
end
of
the
cylinder.
Remove
the
secondary
seal
(8) by
stretching
It
over
the
flange
of
the
piston.
Renew
all seals,
and
check
the
bore
of
the
cylinder
for
deep
score
marks.
If
such
damage
Is
apparent,
a
new
cylinder
should
be
fitted.
It
Is
important
that
all
parts
are
meticulously
cleaned
with
brake
fluid
before
assembly.
Do
not
use
petrol,
trichlorethylene,
or
any
other
cleaning
agents
to
wash
the
parts.
Fit
the
secondary
seal (8)
onto
the
piston
(2),
so
that
the
lip
of
the
seal faces
towards
the
head
(drilled
end)
of
the
piston.
Gently
work
the
seal
around
the
groove
with
the
fingers,
to
ensure
that
It Is
properly
seated.
Fit
the
spring
retainer
(9)
onto
the
small
end
of
the
spring
(4)
and
the
check
valve (3) Onto
the
large end. Insert
the
spring
assembly
onto
the
cylinder bore, large end
first
..
Insert
the
primary
seal (5) Into
the
cylinder
bore,
lip
foremost
taking
care
not
to
damage
or
tUrn back lip.
The
piston
washer
(7)
should
then
be
Inserted
into
the
barrel
with
the
dished side
towards
the
primary
seal (5)
followed
by
the
piston,
head
(drilled
end)
Innermost.
Push
the
piston Inwards
with
the
end
of
the
push
rod,
and refit
the
cirdlp
(6)
making
sure
that
the
c1rdlp beds evenly
In
Its
groove.
Refit
the
boot
(10)
by
stretching
It
over
the
barrel.
Refit
the
reservoir
bowl,
not
forgetting
the
0 ring,
and
test
the
cylinder by filling
the
reservoir,
and
pushing
the
push rod and piston
inwards,
allOWing It
to
return
unassisted.
After
a
few
applications,
fluid
should flow
from
the
outlet
connection at
the
cylinder end.
Fit
the
return
spring.
Empty
the
cylinder
of
fluid,
and
proceed
to
reassemble
the
cylinder
barrel
Into
the
switch housing.
At
this
stage
the
final
position
of
the
cylinder barrel in
the
housing
must
be
determined.
It will be
noted,
from
Fig.
FS,
that
the
lip
of
the
primary seal (5)
must
be
+.
in.
behind
the breather port,
and
the
reservoi r
set
at
an
angle
of10'
to
the
vertical.
The
milled flats
on
the
threaded
end
of
the
cylinder
are
machined
relative
to
the
10'
pOSition, and
the
appropriate
one
must
be used
when
assembly
takes
place.
The
following
method
can
be
used
to
determine
the
correct
linear pOSition
of
the
cylinder
barrel.
(a) Remove
the
reservoir
from
the
cylinder.
(b) Reassemble
the
front
brake
lever
and
push
rod
to
the
switch
hOUSing.
(c)
Screw
the
cylinder
barrel
Into
the
switch
housing, whilst holding
the
brake
lever
In
the
closed position. until It will screW no
further.
F9
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