Prepare
1. Drain front or rear brake system. See Bleed brakes.
Remove
Front Brake Line
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.
1. Remove headlamp fairing. See Headlamp fairing.
2. Disconnect front brake line from front brake master cylinder. See Front brake master cylinder.
3. Disconnect front brake line from front brake caliper. See Front brake caliper.
4. See Figure 3-32. Remove front brake line.
- a. Remove screw (4).
- b. Remove front brake line (1).
- c. Remove clamp (3) from front brake line.
Rear Brake Line
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.
1. Disconnect rear brake line from rear brake master cylinder. See Rear brake master cylinder.
2. Disconnect rear brake line from rear brake caliper. See Rear brake caliper.
3. See Figure 3-33. Remove rear brake line.
- a. Remove screw (1).
- b. Remove rear brake line (2).
- c. Remove clamp (3) from rear brake line.
Figure 3-32. Front Brake Line: 1. Front brake line; 2. Lower fork bracket; 3. Clamp; 4. Screw
Figure 3-33. Rear Brake Line:1. Screw; 2. Rear brake line; 4. Rear fork; 3. Clamp
Install
| FASTENER | TORQUE VALUE | |
| Front brake line clamp screw | 7.2-8.8 Nm | 64-77 in·lbs |
| Rear brake line clamp screw | 7.2-8.8 Nm | 64-77 in·lbs |
Notice: Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly.
Front Brake Line
1. Connect front brake line to front brake master cylinder. See Front brake master cylinder.
2. See Figure 3-32. Install front brake line.
- a. Install clamp (3) to front brake line (1). Hand-tighten.
- b. Insert screw (4) through clamp.
- c. Install clamp to lower fork bracket (2). Tighten to 7.2-8.8 Nm (64-77 in·lbs).
3. Connect front brake line to front brake caliper. See Front brake caliper.
4. Install headlamp fairing. See Headlamp fairing.
Rear Brake Line
1. Connect rear brake line to rear brake master cylinder. See Rear brake master cylinder.
2. Connect rear brake line to rear brake caliper. See Rear brake caliper.
3. See Figure 3-33. Install rear brake line.
- a. Install clamp (3) to rear brake line (2). Hand-tighten.
- b. Insert screw (1) through clamp.
- c. Install clamp to rear fork (4). Tighten to 7.2-8.8 Nm (64-77 in·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 brake lines.
- a. Inspect metal lines for wear. Replace as necessary.
- b. Inspect all fittings for wear. Replace as necessary.
- c. Inspect brake lines for wear or damage. Replace as necessary.
Complete
1. Fill and bleed brake system. See Bleed brakes.