Front Master Cylinder Inspection; Front Master Cylinder Installation - Honda TRX500FM Service Manual

Align the edge of
the master cylinder
with the punch
mark
{51
on the
handlebar.
Connect the gray
Jape (4J wire
connectors
10
the
upper terminals.
BRAKE SYSTEM
INSPECTION
Check the piston cups and boot for wear, deterioration , - - - - - - - - -- - - - - -- - - - - - ,
or damage.
Check the spring for damage.
Check the master cylinder and piston for scoring.
scratches or damage.
Measure the master cylinder 1.0.
SERVICE LIMIT : 14.055 mm (0.5533 in)
Measure the master piston O.D.
SERVICE LIMIT: 13.945 mm (0.5490 in)
INSTALLATION
Instalilhe brake master cylinder [1] and holder [2] with
the "UP· mark facing up. Tighten the upper bolt
f3J
first,
then lighten the lower bolt [4] to the speCified torque.
TORQUE : 12 N'm (1.2 kgf-m , 9 IbUt)
Set the brake hose joint between the stopper groove in
the master cylinder.
Connect the brake hose with the oil bolt [6] and new
sealing washers
(7] .
and tighten the oil bolt to the
specified torque,
TORQUE: 34 N'm (3.5 kgf'm , 25 Ibf-ft)
Connect the connectors [1] to the switches [2].
Insta!1 the dust cover {3] properly.
Fill and bleed the hydraulic system (page 18-7).
(1(
[21
(for starting inhibitor)
I-
_ 131
(4(
(21
(for brake light)
18-11