Removal
Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
1. Remove the rider's seat (see page 16-13).
2. Disconnect the battery, negative (black) lead first.
Caution: To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.
3. Remove the two fixings and remove the heel guard.
4. Drain the fluid from the master cylinder. by bleeding the system at the rear caliper until all fluid has been expelled.
5. Remove the clip from the clevis pin at the lower end of the brake pushrod.
6. Remove the clevis pin.
7. Disconnect the rear brake light switch.
8. Remove the rear brake light and disconnect the rear brake hose from the master cylinder, noting its orientation.
9. Remove the screws securing the master cylinder to the frame and detach the master cylinder.
1. Master cylinder; 2. Master cylinder fixings; 3. Clevis pin; 4. Ciip
10. Disconnect the reservoir hose and remove the master cylinder.
Disassembly
1. Remove the boot from the cylinder and pushrod.
2. Remove the circlip retaining the pushrod to the cylinder.
3. Remove the pushrod and piston set from the master cylinder bore, noting the relative position of the seals and piston components.
Inspection
1. Visually inspect the master cylinder bore for wear, scratches or corrosion. Replace as necessary.
2. Check the piston and cylinder bore for damage, wear or deterioration. Replace as necessary.
3. Always renew the piston and seal set if the cylinder is dismantled.
4. Examine the pushrod for bends and damage. Replace as necessary.
Assembly
Warning: Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking eM.cie.i cy resulting in an accident.
Warning: Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
1. Clean the master cylinder bore, piston and seals, with new brake fluid.
2. Ensure all ports are clear of obstruction.
Warning: Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to an accident could result from incorrect assembly of the master cylinder.
3. Install the spring and piston set together.
4. Apply a small amount of brake grease to the pushrod.
5. Install the pushrod in the master cylinder and retain with a new circlip.
6. Refit the boot.
1. Reservoir hose; 2. Piston set; 3. Dust boot; 4. Push rod; 5. Clevis pin; 6. Ciip; 7. Circlip
7. If the pushrod has been disassembled, adjust the length of the pushrod as shown below:
1. Pushrod; 2. Locknut
8. Set the pushrod free length to 75.5 mm.
9. Tighten the locknut to 18 Nm.
Installation
1. Fit the reservoir hose to the master cylinder.
2. Secure the master cylinder to the frame. Tighten the securing screws to 16 Nm.
3. Connect the push rod to the brake pedal using a new clevis pin and clip.
4. Incorporating new washers, fit the brake hose to the master cylinder. Ensuring correct orientation of the brake hose, tighten the brake light switch to 15 Nm.
Warning: Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual.
5. Fill and bleed the rear brake system (see page 14-23).
6. Refit the heel guard, tightening the fixings to 12 Nm.
7. Reconnect the battery, positive (red) lead first.
8. Refit the rider's seat (see page 16-13).
9. Check for correct brake operation. Rectify as necessary.
Warning: lt is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.