Service manual

FRONT BRAKE
4-28
• Union bolt “1”
• Copper washers “2”
•Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace.
• Brake master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
•Brake hoses
Cracks/damage/wear → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
WARNING
EWA13520
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
EAS22740
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder “1”
• Brake master cylinder bracket “2”
NOTE:
• Install the brake master cylinder holder with
the “UP” mark “a” facing up.
• Align the end of the brake master cylinder
holder with the punch mark “b” on the han-
dlebar.
• First, tighten the upper bolt, then the lower
bolt.
• There should be more than 11 mm (0.43 in)
for clearance between the right handlebar
switch and the brake master cylinder bracket.
Also, the punch mark should be seen.
2. Install:
• Copper washers
•Brake hose
• Union bolt
WARNING
EWA13530
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
"CABLE ROUTING" on page 2-39.
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
Recommended fluid
DOT4
Brake master cylinder bracket
bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)