FRONT BRAKE
4-18
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21.
6. Check:
• Brake fluid level
The minimum level mark or below Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-26.
7. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-22.
• Brake lever operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21.
EAS1SM5145
REMOVING THE FRONT BRAKE MASTER
CYLINDER
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:
• Union bolt
• Copper washers
• Brake hoses
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS1SM5146
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder “1”
Damage/scratches/wear Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body)
Obstruction Blow out with compressed
air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear Replace.
3. Check:
• Brake master cylinder reservoir cap
4. Check:
• Brake hoses
Cracks/damage/wear Replace.
EAS1SM5147
ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
EWA13520
• 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.
1. Wash the brake master cylinder and the
brake master cylinder kit with brake fluid.
2. Install:
• Primary cylinder cup “1”
• Secondary cylinder cup “2”
Install to the brake master cylinder piston
“3”.
EWA13520
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.
Recommended brake fluid
DOT 4
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