Front Master Cylinder Disassembly
- Remove the front master cylinder (See Front Master Cylinder Removal in the Brakes chapter).
- Remove the reservoir cap and diaphragm, and pour the brake fluid into a container.
- Unscrew the locknut and pivot bolt, and remove the brake lever.
- Pull the dust cover [A] out of place, and remove the circlip [B].
Special Tool - Inside Circlip Pliers: 57001-143
- Pull out the piston [C], secondary cup [D], primary cup [E], and return spring [F].
- KLE650A Models [G]
- KLE650B Models [H]
Caution: Do not remove the secondary cup from the piston since removal will damage it.
Rear Master Cylinder Disassembly
Note: Do not remove the push rod clevis for master cylinder disassembly since removal reguires brake position adjustment.
- Remove the rear master cylinder (See Rear Master Cylinder Removal in the Brakes chapter).
- Slide the dust cover on the push rod out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
- Pull out the push rod with the piston stop.
- Take off the piston [A], secondary cup [B], primary cup [C] and return spring [D].
Caution: Do not remove the secondary cup from the piston since removal will damage it.
Master Cylinder Assembly
- Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.
Caution: Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
- Apply brake fluid to the new parts and to the inner wall of the cylinder.
- Take care not to scratch the piston or the inner wall of the cylinder.
- Tighten the brake lever pivot bolt and locknut.
- Apply silicone grease.
Brake Lever Pivot Bolt
Tighten:
- Torque-Brake Lever Pivot Bolt: 1.0 Nm (0.10 kgf·m 9 in·lb)
- Brake Lever Pivot Bolt Locknut: 5.9 Nm (0.60 kgf·m 52 in·lb)