FRONT MASTER CYLINDER

REMOVAL

FRONT MASTER CYLINDER

SEALING WASHERS

OIL BOLT

Drain the front brake hydraulic system (page 16-6).

Remove the brake hose oi and brake hose eyelet.

bolt, sealing washers

When removing the brake hose oil bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out.


Remove the bolts, holder and master cylinder assembly.

MASTER CYLINDER

FRONT MASTER CYLINDER

HOLDER

BOLTS

DISASSEMBLY

DUST COVER PIVOT BOLT/NUT

FRONT MASTER CYLINDER

BRAKE LEVER

Remove the dust cover.

Remove the pivot bolt/nut and brake lever assem­bly.

Remove the boot.

BOOT

FRONT MASTER CYLINDER

Remove the snap ring from the master cylinder body using the special tool as shown.

TOOL:

Snap ring pliers 07914-SA50001

Remove the washer, master piston and spring.

WASHER

INSPECTION

SPRING

FRONT MASTER CYLINDER

PISTON

Clean the inside of the cylinder and reservoir with brake fluid.

Check the piston boot, primary cup and secondary cup for fatigue or damage.

Check the master cylinder and piston for abnormal scratches.

о

Measure the master cylinder I. D. SERVICE LIMIT: 11.050 mm (0.4350 in)

FRONT MASTER CYLINDER

Measure the master piston O. D. SERVICE LIMIT: 10.840 mm (0.4268 in)

FRONT MASTER CYLINDER

ASSEMBLY

Replace the piston, cups, spring, snap ring and boot as a set; do not substitute individual parts.

PISTON

WASHER

FRONT MASTER CYLINDER

Dip the piston and master cylinder I. D. in brake fluid.

Install the spring to the piston.

When installing the cups, do not allow the lips to turn inside out

Install the piston assembly into the master cylinder.

Install the snap ring using the special tool.

TOOL:

Snap ring pliers 07914-SA50001

Apply silicone grease to the inside of the boot. Install the boot to the master cylinder.

Install the brake lever.

Apply silicone grease to the pivot bolt sliding sur­face.

Install and tighten the pivot bolt to the specified torque.

TORQUE: 1.0 N m (0.1 kgf m, 0.7 lbf-ft)

Tighten the pivot nut to the specified torque. TORQUE: 5.9 N-m (0.6 kgf m, 4.4 lbf-ft)

Install the dust cover.

INSTALLATION

Place the master cylinder assembly on the handle­bar.

Align the end of the master cylinder with the paint mark on the handlebar.

Install the master cylinder holder with the "UP" mark facing up.

Tighten the upper bolt first, then the lower bolt to the specified torque.

TORQUE: 9.9 N m (1.0 kgf m, 7.3 lbf-ft)

SNAP RING

FRONT MASTER CYLINDER

Be certain the snap ring is firmly seated in the groove.

BOOT

DUST COVER PIVOT BOLT/ NUT

FRONT MASTER CYLINDER

BRAKE LEVER

MASTER CYLINDER PAINT MARK

HOLDER

BOLTS

FRONT MASTER CYLINDER

FRONT MASTER CYLINDERAlign the brake hose eyelet between the stoppers. Install the brake hose eyelet with the oil bolt and new sealing washers.

BRAKE HOSE

OIL BOLT

Tighten the brake hose oil bolt to the specified torque.

TORQUE: 34 N m (3.5 kgf m, 25 Ibf ft)

Fill and bleed the front brake hydraulic system (page 16-7).

SEALING WASHERS

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