Prepare
1. Remove main fuse. See Power disconnect.
2. Drain brake fluid from front brake system. See Bleed brakes.
Remove
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.
Figure 3-28. Front Brake Master Cylinder: 1. Brake master cylinder assembly; 2. Mounting clamp; 3. Screw (2); 4. Washer (2); 5. Brake line; 6. Banjo bolt; 7. Brake lamp switch connector (2); 8. Handlebar
Install
| FASTENER | TORQUE VALUE | |
| Front brake master cylinder clamp screw | 9.0-12.0 Nm | 80-106 in·lbs |
| Front brake master cylinder banjo bolt | 17.0-20.0 Nm | 13-14 ft·lbs |
1. See Figure 3-28. Install front brake master cylinder.
- a. Align front brake master cylinder assembly (1) to handlebar (8).
- b. Install mounting clamp (2) and clamp screws (3). Tighten to 9.0-12.0 Nm (80-106 in·lbs).
- c. Connect front brake lamp switch connector (7).
Notice: Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly.
2. Install front brake line.
- a. Install banjo bolt (6), new washers (4) and brake line (5) to brake master cylinder. Tighten to 17.0-20.0 Nm (13-14 ft·lbs).
Clean and inspect
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.
1. Clean all parts thoroughly.
2. Inspect front brake master cylinder for leaks. Replace as necessary.
3. Inspect front brake lever for wear or damage. Replace as necessary
Complete
1. Fill and bleed brake front brake system. See Bleed brakes.
2. Install main fuse. See Power disconnect.