HOME 2.13 CLUTCH FLUID LINE REMOVAL Inspect the clutch fluid line for wear, damage, and leaks. Replace if necessary. Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c) 1. Remove secondary clutch actuator cover from left side clutch cover. Be sure no clutch fluid gets on tires, wheels or brakes when draining fluid. Traction can be adversely affected, which could result in loss of control and death or serious injury. (00295a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact.
In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical atten- tion. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) 2. Place a suitable container under secondary clutch actuator. Loosen flare nut and allow clutch fluid to drain from clutch line. NOTE Dispose of clutch fluid in accordance with local regulations. D.O.T. 4 hydraulic brake fluid is used in the hydraulic clutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00353a) 3.
Remove banjo bolt and two copper washers to disconnect fitting of hydraulic clutch fluid line from clutch reservoir and master cylinder. Discard washers. 4. See Figure 2-30 . Remove clutch fluid line from clips on frame. NOTE Note locations and number of cable straps used prior to disas- sembly. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed. Failure to comply can result in cosmetic damage. (00239b) 5. Carefully thread banjo fitting end of clutch line out through upper triple clamp.
Thread flare nut end of clutch line out through bottom of motorcycle and remove clutch line through front down tubes. sm04984 INSTALLATION 1. Route clutch line banjo fitting up through upper triple clamp, then route line behind steering head over to right frame rail and along inside of rail under engine and back up between bottom frame rails to loop out and forward to secondary clutch actuator mounted on clutch cover. 2. Thread in and finger tighten flare nut fastening clutch fluid line to secondary clutch actuator. 3. Attach banjo fitting of the clutch fluid line to master cylinder with new copper washers. 4.
Install all cable straps and ties that were removed during disassembly in their original locations. Be sure no clutch fluid gets on tires, wheels or brakes when adding fluid. Traction can be adversely affected, which could result in loss of control and death or serious injury. (00294a) Figure 2-30. Clutch Fluid Line Clips and Ties 2-32 2009 VRSC Service: Chassis