TGB BLADE 250 Service Manual page 191

16. REAR BRAKE & REAR WHEEL & REAR CUSHION
Measure the outer diameter of the piston. Replace
the piston if its measured value exceeds allowable
limit.
Allowable limit:
Hand brake 13.954 mm
Foot brake 15.850 mm
Master Cylinder Assembly
Caution
● It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
● Make sure there is no dust on all components
before assembling.
Apply clean brake fluid to the piston cup, and then
install the cup onto the piston.
Install the larger end of the spring onto the master
cylinder.
The master cup's cavity should be face inside of
master cylinder when installing the master cup.
Install the cir clip.
Caution
● Never install cup lip in the opposite direction.
● Make sure the cir clip is seated securely in
the groove.
Install the rubber boot into groove properly.
Master Cylinder Install
Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Kink of brake leads, hose or pipe may reduce
brake performance.
Handle left side – rear brake master cylinder A
Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.
Install the brake lever, and connect coupler to
brake light switch.
Connect brake hoses with 2 new washers.
Tighten the brake hose bolt to the specified torque
value.
Torque: 3.5kgf-m
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
so avoid to twisting them together.
Add specified brake fluid and bleed the system.
16-16
To this chapter contents
Rubber boot
Cir clip
Piston
Piston cup
Spring
Brake light switch coupler
Master cylinder
2 socket bolts
Brake lever bolt
Brake lever nut