HOME DISASSEMBLY 5. See Figure 2-40 . Using hand pressure, push down on spring (6) and remove small retainer clip (8), washer (9) and remove spring. TOOL NAME PART NUMBER HOSE CLAMP PLIERS HD-41137 6. Using hand pressure, push in push rod (3). Using a snap ring pliers, remove large retainer clip (5) and retainer washer (4). 7. Remove push rod (3). 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) 8. Remove piston valve assembly (2) from cartridge housing (1). CLEANING AND INSPECTION 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) 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) 1. See Figure 2-39 .
Remove reservoir cover (5) and gasket (6). 1. Clean all rubber parts using denatured alcohol. Check dust boot for cuts or tears. Replace as necessary. 2. Inspect threads on the cartridge body. Replace if threads are damaged. assembly. DO NOT use this grease on internal master cylinder parts. Figure 2-40. Master Cylinder Components 2. Over suitable container, use HOSE CLAMP PLIERS (Part No. HD-41137), to remove hose clamps (8) from reservoir hose (3). Drain reservoir (7) and hose. 4. Insert ball end of push rod (3) into piston valve assembly (2). Using hand pressure, push down to compress spring.
Install retainer washer (4), and larger retainer clip (5) using snap ring pliers into groove of cartridge housing. 3. Thoroughly clean exterior of master cylinder assembly with denatured alcohol. 5. Verify larger retainer clip has seated in groove of cartridge housing body. 4. Gently pull dust seal (17) from cartridge housing (10). 2009 VRSC Service: Chassis 2-43 sm02075 7 5 9 8 6 3 4 2 1 1. Cartridge housing (shown w/elbow and o-ring) 2. Piston valve assembly (see VRSC parts manual) 3. Push rod 4. Retainer washer 5. Retainer clip (large) 6. Spring 7. Dust seal 8. Retainer clip (small) 9. Washer 3. Inspect spring for cracks or broken coils. Replace as necessary. 4.
Wipe bore of cartridge housing with D.O.T. 4 BRAKE FLUID. 5. Inspect reservoir cover gasket for cuts, tears or general deterioration. Replace as necessary. ASSEMBLY 1. See Figure 2-40. Lubricate inner bore of cartridge housing (1) with D.O.T.4 brake fluid. 2. Install new piston valve assembly (2) from service parts kit. 3. Lay down a clean shop cloth and stand cartridge housing upright. NOTE 6. Using hand pressure, push do small washer (9) and small ret retainer clip into groove on pu ggles when removing or 7. Verify small retainer clip has s ining rings can slip from the on push rod. with enough force to cause 2009 VRS Wear safety glasses or go installing retaining rings.
Reta pliers and could be propelled serious eye injury. (00312a)