Installation

1. Locatethemastercylinder tothehandlebars.

2. Positiontheclamptotherearsideofthehandlebars.

3. Alignthemastercylinder/clampsplitlinewiththedotmarkontheundersideofthehandlebar.

1.Splitline

2.Dotmark

4. Tightentheclampbolts,upperfirstandthenthelowerto15Nm.

15.18 ServiceManual-RocketIll

4. Connect thebrakelightswitch.

12. Resetthebrakeleveradjustertotheoriginalsetting.

13. Examinethesystemforcorrectoperationandfluidleaks.Rectifyasnecessary.

14. Checktheoperationofthefrontbrake.Rectifyasnecessary.

1.Brakelightswitchconnections

6. Positionthebrakeleverensuringthatpivotbossiscorrectlyalignedtothepushrod.

7. Fitandtightenthepivotboltto6Nm,andthelocknutto1Nm.

8. Connectthebrakehosetothemastercylinderincorporatingnewsealing washerstoeachsideoftheunion.Tightentheunionboltto25Nm.

15.Connectthebatterypositive,(red)leadfirst,andrefittheseat.

6. Reconnectandadjustthethrottlecablesasdescribedonpage11.117.

7. Refittherighthandswitchcube. Tightenthescrewsto3Nm.

8. Fillandbleedthefrontbrakesasdescribedonpage15.9.

ServiceManual-RocketIll

15.19

BleedingtheRearBrakes,RenewingBrakeFluid

1. Removethecapfromtherearbleednipple.

2. Attachatransparenttubetothebleednipple.

1. BleedNipple

2. Spanner

3. BleedTube

3. Placetheotherendofthetubeinasuitablereceptaclecontainingnewbrakefluid.

1. RearReservoirLowerLevel

2. RearReservoirUpperLevel

4. Removethe reservoir protectivecover.Unscrewandremovetherearbrakereservoircaptakingcarenottospillanyfluid.

^15.20 SeNiceManual-RocketIll

4. Checktheconditionofthesealingdiaphragm.Replacethediaphragmasnecessary.

1.Diaphragm

4. Releasethebleednipple.Note:

   • Duringbleeding,donotallowthefluidleveltofallbelowthelowerlevelmarkinthereservoir.Ifthelevelisallowedtofallbelowthismark,airmayenterthesystemandthesequence ofbleedingmustberepeated.

5. Slowlydepressthebrakepedaland,holdingthepedalfullydown,closethebleednipple.Repeatsteps7and8untilnomoreairappearsinthebleedtube,maintainingthebrakefluidlevelbetweentheupperandlowerreservoirlevelswhilstbleedingisbeingcarriedout.

6. Whenallairhasbeenexpelled fromthesystem,holddownthebrakepedalandclosethebleednipple.Tightenthenippleto7Nm.

7. Fillthereservoirtothemaximumlevel withnewDOT4fluid.

8. Fitthereservoircoverand diaphragm.Checkforcorrectdiaphragmfitmentbeforefinaltighteningofthecover.

9. Refitthereservoircover.Tightenthefixingsto9Nm.

10. Removethebleedtubefromthenipple.

11. Replacethe bleednippledustcap.

12. Ensurethebrakepedaloperationhas afirmresistivefeeltoit,doesnotfeelspongyandthatthepedalcannotbedepressedthroughitsfullrangeoftravel.Rectifyasnecessary.

13. Checktheoperationoftherearbrake.Rectifyasnecessary.

_- ServiceManual-RocketIll

15.21

RearBrakePads,RearBrakeCaliper

Removal

1. Raiseandsupporttherearofthemotorcycle.

4.Ifremovingthecallipercompletely,disconnectthebrakehose.Otherwise,leavethehoseattached.

2.Releasethewheelspindlenutandwithdrawthespindletoapointwhereitclears thecalipercarrier.

1. Wheelspindle

2. Calipercarrier

3.Releasethetorquereactionboltfromthecalipercarrier,collectingthespacerfrombetweenthewheelandcallipercarrier.

5.Asanassembly,manoeuvrethecalliperandcarrier untilitisclearofthebrakediscandwheel,collectingthespaceronceitisfreedfromthecalipercarrier.

1. Caliper

2. Calipercarrier

6.Removeboth'R'clipsfromthepadretainingpin.Thenremovethepin.

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1. Torquereactionbolt

2. Spacer

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