NOTE:
Before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys-tem.
1. Disconnect:
• Rear brake light switch coupler 2. Loosen:
• Rear brake light switch “1”
3. Remove:
• Rear brake master cylinder bolts
• Rear brake master cylinder 4. Remove:
• Rear brake light switch “1”
• Copper washers “2”
• Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
CHECKING THE REAR BRAKE MASTER CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages (brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir
Cracks/damage → Replace.
• Brake fluid reservoir diaphragm Cracks/damage → Replace.
4. Check:
• Brake hoses
Cracks/damage/wear → Replace.
ASSEMBLING THE REAR BRAKE MASTER CYLINDER
WARNING
Before installation, all internal brake com-ponents should be cleaned and lubricated with clean or new brake fluid.
Never use solvents on internal brake com-ponents.
INSTALLING THE REAR BRAKE MASTER CYLINDER
1. Install:
• Copper washers “1”
• Brake hose “2”
• Rear brake light switch “3”
Proper brake hose routing is essential to in-sure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-33.
When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a”as shown.
2. Fill:
• Brake fluid reservoir
(with the specified amount of the recom-mended brake fluid)
WARNING
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. 4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-tem.
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. 6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC BRAKE” on page 3-17.
Recommended fluid DOT 3 or DOT 4
New
New
Brake pedal position 44 mm
4-34 4-35
REAR BRAKE REAR BRAKE
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.
6. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17.
7. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-tem.
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.
Before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys-tem.
1. Disconnect:
• Rear brake light switch coupler 2. Loosen:
• Rear brake light switch “1”
3. Remove:
• Rear brake master cylinder bolts
• Rear brake master cylinder 4. Remove:
• Rear brake light switch “1”
• Copper washers “2”
• Brake hose “3”
To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages (brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir
Cracks/damage → Replace.
• Brake fluid reservoir diaphragm Cracks/damage → Replace.
4. Check:
• Brake hoses
Cracks/damage/wear → Replace.
ASSEMBLING THE REAR BRAKE MASTER CYLINDER
WARNING
Recommended fluid DOT 3 or DOT 4
INSTALLING THE REAR BRAKE MASTER CYLINDER
1. Install:
• Copper washers “1”
• Brake hose “2”
• Rear brake light switch “3”
WARNING
Proper brake hose routing is essential to in-sure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-33.
CAUTION:
When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a”as shown.
2. Fill:
• Brake fluid reservoir
(with the specified amount of the recom-mended brake fluid)
WARNING
Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-tem.
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.
6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC BRAKE” on page 3-17.
Recommended fluid
Brake pedal position 44 mm
a
4-36 4-37
HANDLEBARS HANDLEBARS
HANDLEBARS
Removing the handlebars
Order Job/Parts to remove Qty Remarks
1 Left grip end 1
2 Handlebar grip 1
3 Clutch switch coupler 1 Disconnect.
4 Left handlebar switch 1
5 Clutch cable 1 Disconnect.
6 Clutch switch 1
7 Clutch lever 1
8 Clutch lever holder 1
9 Right grip end 1
10 Right handlebar switch 1
11 Throttle cable 1 Disconnect.
12 Throttle grip 1
13 Front brake light switch 1
14 Front brake master cylinder holder 1
15 Front brake master cylinder 1
16 Plug 2
17 Handlebar bolt 2
18 Handlebar pinch bolt 2
19 Left handlebar 1
20 Right handlebar 1
For installation, reverse the removal proce-dure.
Removing the handlebars
1 2
3 4
5
6 7 8
9
11
12 13
14
4
20 19
16 17
18 17
16
18
10
10
15
T
.R. 9 Nm (0.9 m•kg, 6.5 ft Ib)•
T
.R. 9 Nm (0.9 m•kg, 6.5 ft Ib)•
LS
LS
LS LS
LS
T
.R. 23 Nm (2.3 m•kg, 17 ft Ib)• T..R 7 Nm (0.7 m•kg, 5.0 ft Ib)•
T
..R 7 Nm (0.7 m•kg, 5.0 ft Ib)•
T
..R 7 Nm (0.7 m•kg, 5.0 ft Ib)•
10
9 Nm (0.9 m•kg, 6.5 ft Ib)• 9 Nm (0.9 m•kg, 6.5 ft Ib)•
23 Nm (2.3 m•kg, 17 ft Ib)• 7 Nm (0.7 m•kg, 5.0 ft Ib)•
7 Nm (0.7 m•kg, 5.0 ft Ib)• 7 Nm (0.7 m•kg, 5.0 ft Ib)•
4-36 4-37
HANDLEBARS HANDLEBARS
HANDLEBARS
Removing the handlebars
Order Job/Parts to remove Qty Remarks
1 Left grip end 1
2 Handlebar grip 1
3 Clutch switch coupler 1 Disconnect.
4 Left handlebar switch 1
5 Clutch cable 1 Disconnect.
6 Clutch switch 1
7 Clutch lever 1
8 Clutch lever holder 1
9 Right grip end 1
10 Right handlebar switch 1
11 Throttle cable 1 Disconnect.
12 Throttle grip 1
13 Front brake light switch 1
14 Front brake master cylinder holder 1
15 Front brake master cylinder 1
16 Plug 2
17 Handlebar bolt 2
18 Handlebar pinch bolt 2
19 Left handlebar 1
20 Right handlebar 1
For installation, reverse the removal proce-dure.
Removing the handlebars
Order Job/Parts to remove Qty Remarks
10
9 Nm (0.9 m•kg, 6.5 ft Ib)• 9 Nm (0.9 m•kg, 6.5 ft Ib)•
23 Nm (2.3 m•kg, 17 ft Ib)• 7 Nm (0.7 m•kg, 5.0 ft Ib)•
7 Nm (0.7 m•kg, 5.0 ft Ib)• 7 Nm (0.7 m•kg, 5.0 ft Ib)•
1 2
3 4
5
6 7 8
9
11
12 13
14
4
20 19
16 17
18 17
16
18
10
10
15
T
.R. 9 Nm (0.9 m•kg, 6.5 ft Ib)•
TR.. 9 Nm (0.9 m•kg, 6.5 ft Ib)•
LS
LS
LS LS
LS
T
..R 23 Nm (2.3 m•kg, 17 ft Ib)• TR.. 7 Nm (0.7 m•kg, 5.0 ft Ib)•
T
.R. 7 Nm (0.7 m•kg, 5.0 ft Ib)•
TR.. 7 Nm (0.7 m•kg, 5.0 ft Ib)•
4-38 4-39
HANDLEBARS HANDLEBARS
REMOVING THE HANDLEBARS