Assembly; Installation - Triumph Rocket III Classic Service Manual

Brakes
Assembly
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 loss
of motorcycle control and an accident could result if this
warning is ignored.
1. Lubricate the piston and cylinder with new, clean
brake fluid.
Ensure that the piston and piston seal are fitted facing
the same way as noted during removal. A dangerous
riding condition leading to loss of motorcycle control
and an accident could result from incorrect assembly of
the master cylinder.
2. Fit the new piston set into the master cylinder and
retain with a new circlip.
ceqw
1. Piston
2. Seals (in correct orientation>
3. Refit the master cylinder dust cover.
Installation
1. Locate the master cylinder to the handlebars.
2. Position the clamp to the rear side of the handlebars.
3. Align the master cylinder/clamp split line with the
dot mark on the upperside of the handlebar.
1. Dotmark
2. Split line
4. Tighten the clamp bolts, upper first and then the
lower to
15 Nm.
5. Connect the brake light switch.
6. Position the brake lever and spring ensuring that the
pivot boss is correctly aligned to the push rod.
Z Fit and tighten the pivot bolt to
1 Nm,
and the
locknut to 6 Nm.
8. Connect the brake hose to the master cylinder
incorporating new sealing washers to each side of
the union. Tighten the union bolt to 25 Nm.
Use only O.O.T. 4 specification brake fluid as listed in
the general information section of this manual. The use
of brake fluids other than those O.O.T. 4 fluids listed in
the general information section may reduce the
efficiency of the braking system leading to loss of
motorcycle control and an accident.
Observe the brake fluid handling warnings given earlier
in this section of the manual.
To prevent body damage, do not spill brake fluid onto
any area of the bodywork. Spilled brake fluid will
damage paintwork.
9. Fill and bleed the front brakes (see page 15-12>.
10. Examine the system for correct operation and fluid
leaks. Rectify as necessary.
11. Check the operation of the front brake. Rectify as
necessary.
15.26
SelVice Manual- Rocket Ill/ Classic / Touring