Assembling The Front Brake Master Cylinder; Installing The Front Brake Master Cylinder - Yamaha Grizzly550 User Manual

4. Check:
• Brake hoses
Cracks/damage/wear → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
EWA28P1008
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
• Whenever a master cylinder is disassem-
bled, replace the brake master cylinder kit.
Recommended fluid
DOT 4
EAS22530
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder "1"
• Brake master cylinder holder "2"
Brake master cylinder holder bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
TIP
• Align the end of the brake master cylinder hold-
er with the punch mark "a" on the handlebar.
• Install the brake master cylinder holder with the
"UP" mark "b" facing up.
• Install the brake master cylinder holder so that
the gaps between the brake master cylinder
and the brake master cylinder holder are
equal.
1
a
2. Install:
• Brake hose
New
• Copper washers
• Brake hose union bolt
2
b
4-30
Brake hose union bolt
27 Nm (2.7 m·kg, 19 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-33.
TIP
• 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 other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
3. Install:
• Front brake lever cover "1"
M MMM M MMM M M MMM M M MMM M
a. Spread apart the top and bottom of the front
brake lever cover and fit the cover onto the
front brake lever.
b. While keeping the top of the front brake lever
cover horizontal, push straight down on the
cover and fit the hole "a" in the cover over the
bolt head.
TIP
• Do not fit the hole "b" in the front brake lever
cover over the nut at this time.
• The hole "a" in the front brake lever cover is
smaller than the bolt head; therefore, the hole
will expand as it fits over the bolt head.
a
b
FRONT BRAKE
60˚
M MMM M M MMM M MMM
1
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