HOME formed. Failure to comply can result in cosmetic damage. (00239b) Figure 2-27. Clutch Master Cylinder Components NOTE Do not use a wire or sharp instrument to clean drilled oil pas- sages. ASSEMBLY 7. Inspect cylinder housing bore for scoring, pitting or corro- sion. Also check outlet port for damage. Replace housing if necessary. To rebuild clutch master cylinder, use the components found in the service parts kit. 1. See Figure 2-27 . Lightly lubricate inside of primary cup (5) and fit over lip on spring end of piston (2) so the closed end (small ID) contacts evenly with the shoulder (3) in primary cup grove (6). 8.
Inspect the cover, sight glass, and gasket for cuts, tears or general deterioration. 2. Lightly lubricate inside of secondary cup (7) (steep taper from center to outside diameter) and fit over the lip on outboard end of piston (2) so that flared end is open toward the shoulder (3) of the secondary cup groove (8). 3. Install boot (1), large sealing ID first, on piston (2) until seal on smaller ID fits snugly into thin groove in piston. NOTE See Figure 2-27 . The flared ends of the primary cup and the secondary cup face the spring end of the piston. 2009 VRSC Service: Chassis 2-29 Wear safety glasses or goggles when removing or installing retaining rings.
Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 3. Remove retaining ring from pivot pin groove. NOTE To take the piston spring load off the pin and remove the pivot pin, gently force the clutch lever toward the piston (as if oper- ating the clutch). 4. Remove pivot pin through top of housing. Remove and save pivot pin and clutch lever. 5. See Figure 2-27. Using a toothpick or small screwdriver, gently pry outer edge of piston boot (1) out of piston bore. 6. Remove piston (2) and spring (4). 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) 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) 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- sm04960 2 1 7 8 5 3 6 4 1. Boot 2. Piston 3. Shoulder 4. Spring 5. Primary cup 6.
Groove - primary cup 7. Secondary cup 8. Groove - secondary cup