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BRAKES
405
6. Remo ve the
top cover
and
diaphragm from the
master
cylinder.
7.
Use a clean
syringe to remove
the
brake
fluid
from
the reservo
ir.
Discard
the
brake fluid.
8. Slide the
rubber
boot (Figure
63)
off
the
brake
hose
titling.
9. Remove the banjo
bolt and sealing washers (B.
Figure 62)
sec
uring the
upper brake hose to the
master
cy
linder.
Place
the
loose
end
of the upper
brake hose
in
a reclosable plastic bag
and seal it
to
prevent
contamination and the discharge
of brake
flu id, Sec
ure
the hose to
the
handlebar in the
upright
position.
10. Remove
the clamp
bolts
(Figure 61)
and re-
move
the master
cylinder
from
the
handlebar.
11.
If
the master
cylinder
is being removed
and
is
not
going
to be
serviced,
place
it
in
a rcclosable
plastic bag
and
seal it.
12
.
Install
by reversing these removal
steps
while
noting the following:
a. Move the master cy
linder to a
position
where
the brake lever
suits
the
desired riding
posi-
tion.
then
tighten
the
clamp bolts.
b.
Attach
the
brake hose to the master cylinder
with
the
banjo bolt
and new
sealing
washers.
Tighten
the
banj o
bolts
to
the torque
specifi-
cation listed
in
Table
2.
e.
Retill
the
master
cylinder with DOT
3
brake
fluid
and
bleed the brake as described
in this
chapter.
WARNING
Do not ride the
vehicle until
the
brakes (Ire working
properly.
Make
stlre that
the
brake
lever travel is not
excess
ive and that
the lever does not
feel soft or spo
ngy.
If
either condition
exists,
bleed the
system again.
Disassembly
Refer to
Figure 64
for 1996-
J
998 models and
to
Figure 65
for 1999-on models.
NOTE
There are
no new
or service
limit
specificationsfor
thefront master
C)
'1-
imler
assembly.
I.
Remove the master
cylinder
'IS
described
in
this
chapter.
II
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