2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Replacement
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
When removing the brake pipes and hoses on the hy-
draulic unit, remove them with the flare nut wrench ac-
cording to each assembly of the exploded view in the
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Rear Fender (see Rear Fender Removal in the Frame
Brake Pipe Joint Nuts [A]
Brake Hose Banjo Bolts [B]
Brake Hose Bolts [C]
When removing the brake hoses and pipes, note the fol-
Take care not to spill the brake fluid on the painted or
Temporarily secure the end of the brake hose or pipe to
some high place to keep fluid loss to a minimum.
Immediately wash away any brake fluid that spills.
When installing the brake hoses and pipes , note the fol-
There are washers on each side of the brake hose and
pipe fitting. Replace them with new ones when installing.
Check to see that there is no damage on the threads of
the brake pipe joint nut.
If there is any damage, replace the damaged parts with
Tighten the brake pipe joint nut at both ends of the brake
pipe temporarily and then tighten them to the specified
Install the brake pipes and brake hoses to the specified
angle (see Cable, Wire, and Hose Routing section in the
Tighten the brake pipe joint nuts with the flare nut wrench.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)
Brake Hose Bolts: 8.0 N·m (0.82 kgf·m, 71 in·lb)
Fill the brake line after installing the brake hose and pipe
(see Brake Fluid Change).