General
Warning! Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause brake failure, which could result in death or serious injury.
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.
Notice: Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage.
Front brake hand lever and rear brake foot pedal must have a firm feel when brakes are applied. If not, bleed system as described.
Procedure
| PART NUMBER | TOOL NAME |
| SNAP-ON BB200A | BASIC VACUUM BRAKE BLEEDER |
| FASTENER | TORQUE VALUE | |
| Brake caliper bleeder valve | 35-61 in·lbs | 4.0-6.9 Nm |
| Brake master cylinder, front, reservoir cover screws | 9-17 in·lbs | 1.0-2.0 Nm |
Note. If the brake system was completely drained, use the BASIC VACUUM BRAKE BLEEDER (Part No. Snap-On BB200A). Refer to the instructions provided with the tool. If a vacuum brake bleeder is not available, use the following procedure.
1. Remove bleeder valve cap. Install end of clear plastic tubing over bleeder valve and place free end in a clean container.
2. Position vehicle or handlebar so master cylinder reservoir is level.
Note. Protect paint from brake fluid spills. Wrap a clean shop cloth around the outside of the master cylinder reservoir.
3. Remove cover from master cylinder reservoir.
Warning! A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury.
4. Refer to Table 2-18. Add brake fluid as necessary. Verify operation of the master cylinder relief port by actuating the brake pedal or lever. A slight spurt of fluid will break the surface.
5. Operate the brake lever or pedal to build hydraulic pressure.
Note. Pay careful attention to the level of the fluid in the master cylinder reservoir and add fluid before it empties to avoid drawing air into the brake lines.
6. While holding pressure with the brake lever or pedal:
- a. Open bleeder valve about 3/4 turn.
- b. Close bleeder valve as soon as the lever or pedal has moved full range of travel.
- c. Allow brake lever or pedal to return slowly to its released position.
7. Repeat steps until all air bubbles are purged and a solid column of fluid is observed in the bleeder tube.
8. Tighten bleeder valve to specification. Install bleeder valve cap.
Note. If bleeding a dual caliper brake system, repeat steps to bleed the second brake line and caliper.
9. Check and fill reservoir to specified level.
Note. Check master cylinder cover gasket bellows. Verify that the master cylinder cover gasket bellows is not extended or brake fluid will be ejected from the reservoir.
10. Refer to Table 2-19. Verify gasket and sealing surfaces are free of debris. Install master cylinder reservoir cover: a. Front Master Cylinder Reservoir: Orient the cover with the vent holes facing the rear. Install cover screws and tighten to specification.
b. Rear Master Cylinder Reservoir: Install cover screws and tighten to specification.
Note. Dispose of used brake fluid in accordance with local regulations.
11. Verify stop lamp operation.
Warning! After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury.
12. Test ride motorcycle. Repeat the bleeding procedure if brakes feel spongy.
Table 2-18. Fluid level
| ITEM | SPECIFICATION |
| Front reservoir | Boss or ridge |
| Rear reservoir | Ledge or range window |
Table 2-19. Torque specifications
| COMPONENT | TORQUE |
| Bleeder | 35-61 in·lbs (4.0-6.9 Nm) |
| Front cover | 9-17 in·lbs (1.0-2.0 Nm) |
| Rear cover | Hand tighten |