HOME 2.11 CLUTCH MASTER CYLINDER AND RESERVOIR GENERAL 6. Remove banjo bolt (6) and two copper washers (7) to disconnect fitting of hydraulic clutch fluid line (5) from clutch reservoir and master cylinder. Discard copper washers. The clutch is hydraulically actuated. Squeezing the clutch hand lever causes the clutch master cylinder to apply pressure via the clutch fluid in the clutch line to the secondary clutch actuator mounted to the engine right side cover. The secondary clutch actuator piston extends and contacts the clutch release bearing which disengages the clutch.
NOTE To prevent the rest of the clutch fluid from draining from the clutch line and secondary clutch actuator, support the banjo fitting and clutch fluid line upright. Plug the banjo bolt hole with a finger to transfer the assembly to a workbench without spilling clutch fluid. A bleeder screw at the secondary clutch actuator allows bleeding air from the clutch lines. D.O.T. 4 BRAKE FLUID is used in the clutch system. 7. Remove handlebar clamp screws and take clamp and clutch master cylinder/reservoir assembly to a workbench. Check the clutch fluid level in the clutch fluid reservoir on left handlebar.
If the sight gauge is dark, the fluid level in the which could result in loss of control and death or serious injury. (00295a) Figure 2-26. Clutch Master Cylinder/Reservoir NOTES • Place a large cup under the banjo fitting. Hydraulic fluid will begin draining from the reservoir as the banjo bolt is removed. DISASSEMBLY NOTE • Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing clutch line components. To prevent dirt and other contaminants from entering the master cylinder reservoir, thoroughly clean the cover before removal. 1. Drain additional clutch fluid from master cylinder/reservoir. 5.
Slowly loosen banjo bolt (6) and allow clutch fluid from reservoir to drain into cup. 2. Remove screws securing master cylinder cover. Remove cover and gasket. Turn housing upside down to remove remaining clutch fluid from reservoir. NOTE Dispose of clutch fluid in accordance with local regulations. 2-28 2009 VRSC Service: Chassis full. If the sight gauge appears clear, the fluid level is below the sight gauge prism and the fluid level should be checked. Fluid level should be level with the internal shelf marked FILL LEVEL with the motorcycle upright. 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) REMOVAL 1. While holding turn signal locknut underneath clutch lever/master cylinder assembly, unthread mirror (counter- clockwise). Remove mirror and turn signal. 2. Remove electrical controls. NOTE To prevent dirt and other contaminants from entering the master cylinder reservoir, thoroughly clean the cover before removal. 3. See Figure 2-26. Loosen, but do not remove, screws (10) with flat washers (9) that detach handlebar clamp (8) from clutch master cylinder/reservoir. 4. Loosen both screws (3) on cover (1) to relieve pressure in master cylinder reservoir.
Be sure no clutch fluid gets on tires, wheels or brakes when draining fluid. Traction can be adversely affected, sm02044 10 1 9 2 8 7 6 3 4 5 1. Cover 2. Clutch hand lever 3. Cover hold down screws 4. Banjo fitting 5. Clutch fluid line 6. Banjo bolt 7. Copper washers 8. Handlebar clamp 9. Washer 10. Clamp screw