Replacing Brake Fluid And Bleeding The Hydraulic System - Indian Motorcycle Chief 2003 Service Manual

INDIAN CHIEF SERVICE MANUAL
Installation
Thread the new brake line onto the outlet fitting of the
master cylinder and tighten to specification, using a
7/16" wrench. Support the master cylinder outlet
fitting, using a 9/16" wrench, while tightening the
brake line.
Thread the brake line onto the 90-degree fitting on the
front caliper and tighten to specification, using a 7/16"
wrench.
Place the brake line clamp over the brake line. Position
the brake line clamp to the lower fork bracket, install
the clamp bolt and tighten, using a 1/2" wrench.
Make sure all connections are tight and secure.
Add DOT 5 hydraulic brake fluid to the reservoir. Fill
to 1/4" below the top of the reservoir.
USE ONLY DOT 5 BRAKE FLUID. DOT 5 fluid is
silicone based and not compatible with DOT 3, 4 or
5.1. Damage to the brake system will occur if you
install any other fluid.
Bleed the hydraulic brake system. Refer to Replacing
Brake Fluid and Bleeding the System in this section for
procedures.
Check for proper brake operation.
Rear Brake Line Removal and Installation
Removal
Open the bleeder screw on the rear caliper and pump
the rear brake pedal several times to drain the system
of brake fluid. Catch the brake fluid in a suitable
container. Close the bleeder screw.
Remove the rear master cylinder brake switch, along
with the brake line fitting and copper sealing washers,
using a 14 mm open end wrench.
Remove the bolt securing the brake line fitting to the
rear caliper, using a 14 mm wrench. Remove the copper
sealing washers.
Pull the rear brake line out of its routing along the
right-side frame tube. Note the routing of the brake
line for installation purposes.
Installation
Route the new rear brake line as noted during removal.
Make sure the line reaches both front and rear
connections. Install new tie straps to secure the line.
Place the bolt with copper sealing washer through the
caliper fitting of the brake line. Add the second copper
sealing washer onto the bolt.
Thread the bolt into the rear caliper and tighten to
specification, using a 14 mm wrench.
Thread the brake switch into the rear master cylinder
and tighten to specification, using a 14 mm wrench.
Make sure one copper sealing washer is on each side of
the brake line fitting.
Make sure the brake line is captured by the swingarm
hose guide.
Reposition the boot over the brake switch.
Bleed the hydraulic brake system. Refer to Replacing
Brake Fluid and Bleeding the System in this section for
procedures.
Check for proper brake operation.
Replacing Brake Fluid and Bleeding
the Hydraulic System
Over time, the efficiency of the hydraulic brake system
begins to degrade due to moisture. Moisture enters the
system through normal heating and cooling cycles
during brake operation. DOT 5 silicone brake fluid is
non-hygroscopic and does not absorb moisture.
However, excessive moisture in the system can cause
system damage.
The brake fluid should be replaced and the brakes bled
every year to maintain braking efficiency.
Also, the brake fluid should be changed and the system
bled when the hydraulic system has been opened due
to caliper, brake line or master cylinder service.
USE ONLY DOT 5 BRAKE FLUID. DOT 5 fluid is
silicone based and not compatible with DOT 3, 4 or
5.1. Damage to the brake system will occur if you
install any other fluid.
Replacing the brake fluid and bleeding the brakes is
similar for both front and rear brakes. The following
procedure applies to both front and rear brakes.
BRAKE SYSTEM
81