HOME CLEANING AND INSPECTION 2. Press down on piston and spring assembly into the cyl- inder bore and install retaining clip (17) Retaining clip must be completely seated in groove on outlet side of piston bore. Install dust cover (18) and push rod (19). 1. Always assemble master cylinder using new parts from repair kit. 3. Install cover (3) with gasket (4) on master cylinder reser- voir. Snug screws (1) to fasten the cover to reservoir. Do not tighten screws at this time. Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly.
Deterioration of these components can cause brake failure, which could result in death or serious injury. (00291a) 4. Align hole in brake hand lever with hole in master cylinder reservoir (6). From top of assembly, slide pivot pin (7) through reservoir and hand lever. 5. Install retaining clip (10) in pivot pin groove. Verify that retaining clip is completely seated in groove and verify proper function of master cylinder assembly. 2. Clean all parts with denatured alcohol or D.O.T. 4 BRAKE FLUID. Do not contaminate with mineral oil or other solvents. Wipe dry with a clean, lint free cloth.
INSTALLATION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) 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. Blow out drilled passages and bore with a clean air supply.
Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir. 1. See Figure 2-36 . Position brake lever/master cylinder assembly inboard of switch housing assembly engaging tab (2) on lower switch housing (1) in groove (3) at top of brake lever bracket (4). 4. Carefully inspect all parts for wear or damage and replace as necessary. 2. Align holes in handlebar clamp with those in master cyl- inder housing and start both screws with flat washers. Position for rider posture. Beginning with top screw, tighten to 8-9 Nm (71-80 in-lbs ). 5. Inspect piston bore in master cylinder housing for scoring, pitting or corrosion.
Replace master cylinder if any of these conditions are found. 6. Inspect outlet port that mates with brake line fitting. If any scratches, dents or other damage is found on this critical sealing surface, replace housing. 7. Inspect cover, sight glass and gasket for cuts, tears or general deterioration. If gasket and/or sight glass replacement is necessary, proceed as follows: Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) a. From inboard side, push sight glass (5) out of casting. 3. Position new copper washers on each side of hydraulic brake line fitting. Insert bolt through washers and fitting.
Thread banjo bolt into master cylinder housing and tighten to 17-20 Nm (13-15 ft-lbs). b. Pull rubber gasket (4) from cover (3). NOTE Cover gasket is unidirectional and will only fit properly one way.Verify correct installation before completing assembly. 4. Install length of clear plastic tubing over caliper bleeder valve, if removed. Place free end of tube in a clean con- tainer. c. Fit new gasket into cover, aligning gasket and cover thru holes. ASSEMBLY 5. Stand the motorcycle upright so that master cylinder is level. Remove master cylinder cover. To rebuild front brake master cylinder, use the components found in the Service Parts Kit. 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) 1. Install new front master cylinder kit. Kit includes: primary seal, secondary seal, piston valve, and spring as an assembly. NOTE Apply a drop of grease (supplied with brake kit) to each end of push rod before installation. DO NOT use this grease on master cylinder internal parts. 2009 VRSC Service: Chassis 2-37