Removal: XL models
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. Position motorcycle upright on suitable lift.
2. See Figure 2-97. Grasp reservoir cover (2) and gently pull straight out from reservoir (1).
Figure 2-97. Reservoir mount: 1. Rear brake master cylinder reservoir; 2. Reservoir cover; 3. Mounting screw with captive washer; 4. Reservoir cap; 5. Hose clamp; 6. Master cylinder feed hose
3. Remove screw with captive washer (3).
4. Remove reservoir cap (4). Hold reservoir upside down over a suitable container and drain brake fluid.
Note. Dispose of brake fluid in accordance with local regulations.
5. Loosen hose clamp (5). Pull feed hose (6) from reservoir. Slide hose clamp off free end of feed hose.
6. See Figure 2-98. Slide feed hose (2) down through clamp (3). Hold free end of hose down over container and drain any brake fluid remaining in hose.
7. Loosen hose clamp (4). Pull feed hose off feed hose port (5) on master cylinder (1).
8. Cover feed hose port with a clean, lint-free cloth to keep dirt and debris out of master cylinder.
Installation: XL models
| FASTENER | TORQUE VALUE | |
| Brake master cylinder reservoir, rear, mounting screw | 20-25 in·lbs | 2.3-2.8 Nm |
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 BRAKE FLUID contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. See Figure 2-98. Slide end of feed hose (2) onto feed hose port (5) on master cylinder (1). Secure feed hose to fitting with hose clamp (4).
Figure 2-98. Master cylinder feed hose: 1. Rear brake master cylinder; 2. Master cylinder feed hose; 3. Clamp; 4. Hose clamp; 5. Feed hose port
2. Slide free end of feed hose up through clamp (3).
3. See Figure 2-97. Slide hose clamp (5) onto free end of feed hose (6).
4. Push feed hose onto fitting on reservoir (1). Secure with a hose clamp.
5. Install reservoir using screw with captive washer (3). Tighten to 20-25 in·lbs (2.3-2.8 Nm).
Notes:
- Level the rear brake master cylinder reservoir.
- Use only DOT 4 BRAKE FLUID from a sealed container.
- Do not overfill reservoir. Do not reuse old brake fluid.
6. Position motorcycle upright (not resting on jiffy stand). Fill master cylinder reservoir with DOT 4 BRAKE FLUID until the fluid level reaches the UPPER mark on the reservoir.
7. Bleed brake system. See 2.17 BLEEDING BRAKES.
8. Install reservoir cover (2).
9. Verify tail lamp, and stop lamp.
10. Test ride motorcycle. If brake feels spongy, repeat bleeding procedure.
Removal: XR 1200X
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. Position motorcycle upright on suitable lift.
2. See Figure 2-99. Loosen reservoir cap (2).
Figure 2-99. Rear brake master cylinder reservoir: XR 1200X: 1. Rear brake master cylinder reservoir; 2. Reservoir cap; 3. Hose clamp; 4. Feed hose; 5. Hose clamp (master cylinder); 6. Screw
3. Remove screw (6).
4. Remove reservoir cap (2). Hold reservoir upside down over a suitable container and drain brake fluid.
5. Loosen hose clamp (3) and pull feed hose (4) from reservoir. Slide hose clamp off free end of feed hose.
6. Loosen hose clamp (5) and pull feed hose off master cylinder. Cover feed hose port with a clean, lint-free cloth to keep dirt and debris out of master cylinder.
Installation: XR 1200X
| FASTENER | TORQUE VALUE | |
| Brake master cylinder reservoir, rear, mounting screw | 36-60 in·lbs | 4.1-6.8 Nm |
Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. See Figure 2-99. Slide end of feed hose (4) onto feed hose port on master cylinder. Secure feed hose to fitting with hose clamp (5).
2. Slide hose clamp (3) onto free end of feed hose (4).
3. Push feed hose onto fitting on reservoir (1). Secure with a hose clamp.
4. Install reservoir using screw (6). Tighten to 36-60 in·lbs (4.1-6.8 Nm).
Notes:
- Level the rear brake master cylinder reservoir.
- Use only DOT 4 BRAKE FLUID from a sealed container.
- Do not overfill reservoir. Do not reuse old brake fluid.
5. Position motorcycle upright (not resting on jiffy stand). Fill master cylinder reservoir with DOT 4 BRAKE FLUID until the fluid level reaches the UPPER mark on the reservoir.
6. Bleed brake system. See 2.17 BLEEDING BRAKES.
7. Install reservoir cover (2).
8. Verify operation of brake lamp.
9. Test ride motorcycle. If brake feels spongy, repeat bleeding procedure.