HOME 4. Using lubricant in service parts kit, thoroughly coat outside diameters of primary and secondary cups. Coat master cylinder piston bore. sm02046 5. See Figure 2-27 . With tapered end out, install spring (4) into opening on inboard side of piston assembly. 2 3 1 6. Align and install piston assembly into bore. Firmly press on flat end of piston, compressing spring, until the entire assembly slides into cylinder bore. NOTE When fitting the piston sealing boot, be careful not to tear, perforate or damage the piston sealing boot. 1. Boot in piston groove 2. Secondary cup flare 3. Primary cup 7. Compress piston until it is even with the end of bore.
Using a small dull bladed screwdriver or similar tool, gently work around sealing edges of boot until entire circumference of boot is seated in cylinder bore groove. Figure 2-28. Assembled Cups and Piston 8. If cover gasket and/or sight glass replacement is neces- sary. Proceed as follows: INSTALLATION 1. See Figure 2-26 . Attach master cylinder/reservoir to handlebars with handlebar clamp (8). Orient lever to rider position and tighten two clamp screws (10) to 8-9 Nm (71-80 in-lbs ). a. From inboard side, push sight glass toward top of cover until free. b. Pull rubber gasket from cover. c. Fit nipple of new gasket into hole of cover aligning gasket and cover thru holes. 2.
Attach banjo fitting (4) of clutch fluid line to master cylinder with new copper washers. Install electrical controls. d. From bottom of gasket, push flat end of sight glass through nipple until top of glass is flush with top of gasket. Verify that glass is square in bore. If lubrica- tion is necessary, use clean D.O.T. 4 BRAKE FLUID. 3. Remove secondary clutch actuator cover and loosen bleeder screw. 4. Fill reservoir with D.O.T. 4 BRAKE FLUID. Allow fluid to fill clutch line until a steady flow of clutch fluid flows from bleeder screw. Finger tighten bleed screw. 9. Install cover with gasket on master cylinder reservoir.
Install two screws to fasten the cover to reservoir, but do not tighten. 5. Bleed clutch line. See 1.15 BLEEDING CLUTCH FLUID LINE . 6. Verify that fluid level in clutch fluid reservoir is at FILL LEVEL with motorcycle upright. 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) NOTE Clutch fluid volume increases with clutch wear. Do not overfill clutch reservoir. 7. Verify pressure by squeezing clutch hand lever. 10. To install existing clutch hand lever, install clutch hand lever, pivot pin, and a new retaining ring. 8.
Tighten fasteners as follows: 11. To install a replacement clutch hand lever, See a. Banjo bolt (6) to 17-20 Nm (13-14 ft-lbs). 2.12 CLUTCH HAND LEVER . b. Bleeder screw to 9-11 Nm (80-97 in-lbs ). c. Reservoir cover screws to 0.7-0.9 Nm (6-8 in-lbs ). d. Secondary clutch actuator cover mounting bolts to 6- 10 Nm (53-88 in-lbs ). Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury. (00478b) 9. Install rear view mirror and turn signals. 10. Test ride motorcycle. 2-30 2009 VRSC Service: Chassis