Disc Brake - Tracker Off-Road XTR1000 Service Manual

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CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the vehicle.
4. Disconnect the remote reservoir from the master cyl-
inder.
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5. Remove the two cap screws securing the master cyl-
inder to the frame.
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INSPECTING
1. Inspect the master cylinder push rod and clevis for
wear, bending, or elongation of clevis holes.
2. Inspect the push rod boot for tears or deterioration.
3. Inspect the reservoir for cracks and leakage.
4. Inspect the brake hose for cracks and deterioration
and the condition of the banjo-fittings.
INSTALLING
1. Place the master cylinder into position and secure
with cap screws. Tighten to 25 ft-lb (34 N-m).
142
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2. Install the pivot pin and secure with a the E-clip; then con-
nect the spring.
3. Using four new crush washers installed on both sides of
the banjo fitting, secure the banjo bolts into the master cyl-
inder. Tighten to 20 ft-lb (27.2 N-m).
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4. Connect the wires to the pressure switches.
5. Connect the remote reservoir.
6. Fill the master cylinder and bleed the brake system (see
Hydraulic Brake System
nance/Tune-Up).

Disc Brake

REMOVING
1. Remove the wheel and brake caliper; then remove the hub
from vehicle.
2. Remove the four cap screws securing the disc brake to the
hub; then remove the disc brake from the hub.
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INSTALLING
1. Align the disc brake with the hub; then install new cap
screws. Tighten cap screws to 15 ft-lb (20.4 N-m).
2. Install the hub, brake caliper and wheel.
in Periodic Mainte-