HOME 2.15 FRONT BRAKE MASTER CYLINDER/RESERVOIR GENERAL 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) 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) 5.
Remove retaining clip (10) from pivot pin (7) and remove brake hand lever (9) from master cylinder. 6. Remove push rod (19), dust cover (18) and retainer clip (17). 7. Remove piston (15) and spring (11) from master cylinder bore. 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) NOTE To prevent dirt and other contaminants from entering the master cylinder reservoir, thoroughly clean the cover before removal. 8. Remove both screws (1), cover (3) and cover gasket (4). lever and reservoir housing. 4.
See Figure 2-35 . Remove screw (21) to detach handlebar clamp (20) from master cylinder reservoir (6). Figure 2-34. Front Brake Master Cylinder and Reservoir 2009 VRSC Service: Chassis 2-35 REMOVAL AND DISASSEMBLY NOTE Master cylinders designed for dual disc (two caliper) operation have an 15 mm (19/32 in.) bore. 1. Open bleeder nipple caps on front brake calipers. Install clear plastic tubing over each caliper bleeder valve, while placing free ends in a suitable container. Open bleeder valves about 3/4-turn. Pump brake hand lever to drain brake fluid from reservoir. Close bleeder valve. See 1.12 BLEEDING BRAKES. sm02052 1 2 1. Groove 2.
4 mm (5/32 in.) thick cardboard insert , while leeder o drain e. See Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) 2. Remove banjo bolt and two copper washers to disconnect fitting of hydraulic brake line from front brake master cyl- inder. Discard washers. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 3. See Figure 2-34.
Place cardboard insert (2) between brake