Assembling The Front Brake Master Cylinder; Installing The Front Brake Master Cylinder - Yamaha XV19SW Service Manual

• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
1
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace.
• Brake master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Brake hose
Cracks/damage/wear → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
EWA13520
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
Recommended fluid
DOT 4
EAS22530
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Front brake master cylinder "1"
• Front brake master cylinder holder "2"
Front brake master cylinder hold-
er bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
• Align the end of the brake master cylinder hold-
er with the punch mark "a" on the handlebar.
• First, tighten the rear bolt, then the front bolt.
1
2. Install:
• Copper washers
• Front brake hose "1"
• Front brake hose union bolt "2"
Front brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-45.
NOTE:
• Install the brake hose at a right angle to the
front brake master cylinder as shown in the il-
lustration.
• While holding the brake hose, tighten the union
bolt.
• Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 4
4-41
FRONT BRAKE
a
2
New
2
1
10–30˚