6.13
Final Drive and Brakes
6
Brake Line Replacement
Follow these steps if the brake line is to be replaced.
1. If needed bleed the brake system by attaching a clear hose
to the caliper bleed fitting.
2. Attach the other end to a Mity Vac or similar vacuum tool.
3. Bleed the system of brake fluid.
4. Note the orientation of the brake line. The brake line will
need to be replaced in the same orientation.
5. Remove the brake line from the caliper. Cap or cover the
end to catch any brake fluid that may still be in the line.
6. Loosen the brake line from the master cylinder 1/4 to 1/2
turn.
7. Remove the 4 screws that hold the master cylinder to the
handlebar. This will separate the master cylinder from the
switch pack.
8. Unplug the brake light switch harness from the master
cylinder.
9. Remove the brake line from the master cylinder.
10. Install new brake line on caliper and orientate it as noted in
step 4.
11. Torque the caliper banjo bolt to 168-216 in-lb (19-24 N-m).
12. Insert the new brake line and install into the master
cylinder. Torque the brake line to 144-192 in-lb
(16-21 N-m).
13. Tighten the brake line into the master cylinder in an
orientation so that the line does not have any sharp bends
when it is installed on the handlebar.
14. Route the brake light switch in the harness correctly.
15. Place the switch pack with the master cylinder onto the
handle bar. Two smaller screws should be placed on the top
and the longest screw is placed on the lower right.
144-192 in-lb (16-22\N-m)
brake light switch
168-216in-lb (18.9-24.4 N-m)
= T
Caliper Banjo Bolt: 168-216 in-lb (18-24 N-m)
= T
Brake Line: 144-192 in-lb (16-22 N-m)
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