HOME 8. Install dust seal (7) over push rod and seat base of dust seal into bore of cartridge housing until base of seal is below bore opening. window at rear of reservoir. Use only D.O.T. 4 BRAKE FLUID from a sealed container. 9. Test function of master cylinder assembly. Check for binding or excessive drag when pushing down on push rod. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) INSTALLATION 1. See Figure 2-39 . Route remote reservoir (7) and hose (3) behind rear brake pedal (14).
Press reservoir mounting studs into slots on radiator cover. 9. Bleed brake system. See 1.12 BLEEDING BRAKES . 2. Fit square on bottom of master cylinder cartridge housing (10) into square hole of mounting bracket. 10. Install gasket and cover on master cylinder.Tighten cover screws to 0.7-0.9 Nm (6-8 in-lbs ). 11. Reinstall radiator side cover. 3. Install clevis pin (15) through the brake pedal clevis and master cylinder push rod (12). 12. Reinstall maxi-fuse and right side cover. 4. Cover the face of clevis pin and clevis with cardboard. Holding the brake pedal firmly, tap on a rod to seat shoulder of clevis pin into clevis. Install new clip.
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 5. Apply LOCTITE® 243 (blue) to threads of jam nut (9). Thread jam nut on cartridge housing and tighten to 41-54 Nm (30-40 ft-lbs). NOTE To avoid leakage, verify that the banjo bolt, brake line fitting and master cylinder bore are completely clean. 13. Test brake system. a. Turn ignition switch ON. Pump brake foot pedal to verify operation of brake lamp. 6. Lubricate new copper washers (7) with D.O.T. 4 BRAKE FLUID. Position washers on each side of brake line.
Insert the banjo bolt through washers and fitting. Tighten to 23- 26 Nm (17-19 ft-lbs). b. Test ride motorcycle. If the brakes feel spongy, bleed the system again. See 1.12 BLEEDING BRAKES . 7. Stand the motorcycle upright so that the reservoir is in a level position. Clean and remove reservoir cover. sm02076 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 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) 8. See Figure 2-41 . Add D.O.T. 4 BRAKE FLUID to the master cylinder reservoir until the fluid level is 12.7 mm (1/2 in.) below top of reservoir and is visible in sight Figure 2-41. Rear Brake Reservoir Sight Window (removed from motorcycle) 2-44 2009 VRSC Service: Chassis