BOMBARDIER DS 650 Shop Manual page 218

Discard sealing washers.
Unhook push rod no. 19 from brake pedal no. 5.
Remove bolts no. 20 retaining master cylinder to
frame.
1. Master cylinder
2. Flexible hose
3. Rear brake hose
4. Push rod
5. Remove bolts
6. Rear brake switch
7. Rear brake switch connectors
Disassembly
Front Master Cylinder
Remove brake lever no. 4 and locking mechanism
no. 21 for parking brake.
Remove piston boot no. 22, snap ring no. 23,
master piston and spring.
Rear Master Cylinder
Remove boot no. 24 from master cylinder.
Remove snap ring no. 25 and push rod no. 19 us-
ing snap ring pliers.
Remove master piston and spring.
Inspection and Lubrication
Discard any remaining fluid inside reservoir.
Clean reservoirs, master pistons and master cylin-
ders thoroughly with clean brake fluid.
Check:
– boots nos. 22 and 24 for cracks
– springs for damage
– piston cups for wear, deterioration or damage
VMR2004_028_09_02A.FM
Section 09
Subsection 02 (HYDRAULIC BRAKES)
– master cylinders and pistons for scoring, scratch-
es or other damage.
Change part(s) if necessary.
Check locking pin no. 26 for excessive wear, re-
place if necessary.
NOTE: If master cylinder is damaged or leaking,
replace as an assembly.
Assembly
Front Master Cylinder
Coat master piston and piston cups with clean
brake fluid.
Install:
– spring onto master piston
– master piston into master cylinder
– snap ring into groove in the master cylinder
– boot into master cylinder and the groove in pis-
ton.
Apply silicone grease to the brake lever contacting
surface of the piston.
Install brake lever and locking mechanism.
NOTE: Apply silicone grease on lever pivot bolt.
Rear Master Cylinder
For the rear master cylinder use the same proce-
dure that front master cylinder, however pay at-
tention to the following:
If push rod yoke no. 27 is reinstalled, adjust push
rod length, see the following illustration.
A. 3 ± 1 mm (1/8 ± 1/32 in)
Installation
For the installation, reverse the removal proce-
dure, pay attention to the following details.
NOTE: Always replace with standard screw, if
ever the brake hose retaining clip taptite screw
has been removed.
BRAKES
09-02-5