Installation

1. Locatethedisctothewheel.

2. Fitnewsecuringbolts andtightento22Nm.

3. Refitthewheelasdescribedonpage16.9.

4. Checktheoperationofthe rearbrake.Rectifyasnecessary.

1. Removetheseatanddisconnectthebatterynegative(black)leadfirst.

2. Drainthefluidfromthemastercylinderbybleedingthesystemattherearcaliperuntilallfluidhasbeenexpelled.

3. Removethemastercylinderheelguard.

1. Heelguard

2. Heelguardfixings

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15.25

4. Removetheclipfromthebrakepedalclevispin.Removetheclevispin.

1. Pedal

2. Pushrod

3. Clevis

5. Disconnectthefeedhosefromthebrakefluidreservoiratthemastercylinder.

7.Releasetheboltssecuringthemastercylindertothefootrestmountingbar.Detachthemastercylinder.

1. Footrestmountingbar

2. Mastercylinderbolts

Disassembly

1. Removethedustcoverfromthecylinderandpushrod.

2. Removethecirclipretainingthepushrodtothecylinder.

1.Reservoirfeedhose

6. Disconnectthebrakepipefromthecylinder(discardthesealingwashers).

master

1.Circllp

1.Brakepipe

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3. Removethepushrodandpistonsetfromthemastercylinderborenotingtherelativepositionofthesealsandpistoncomponents.

Assembly

1. Lubricatethepistonand cylinderwithnew,cleanbrakefluid.

1.Piston

Inspection

1. Checkthefollowingforwear,damage,cracksordeterioration:

""'

1. Cylinderbore

2. Dustcover

3. Spring

4. Piston

5. Pivotbolt

2. Examinethepushrod fordistortionandotherdamage.Replace asnecessary.

2.Fitthenewpistonandsealsetintothemastercylinder.

1.Piston

2. Seals(Incorrectorientation)

3. Applyasmallamountofbrakegreasetothepushrod.

4. Installthepushrodinthemastercylinder,compressthe springandretainthe assemblywithanewcirclip.

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15.27

1.Pushrod

2.Circlip

5. Refitthemastercylinderboot.

Installation

1.Positionthemastercylindertothefootrestmountingbar.

2. Securewithtwo newbolts,tighteningto27Nm.

3. Incorporatingnewwasherstoeithersideoftheunion,fitthebrakepipe.Tightentheunionboltto25Nm.

4.Positionthereservoirhoseto themastercylinder.Retainthehosebypositioningtheclipsasshownbelow.

5.Alignthebrakepedalwiththepushrod,engagetheclevisandretainitwiththeclip.Ensuretheclipisfittedasshownbelow.

1. Pedal

2. Pushrod

3. Clevis

1. Reservoirhose

2. Clips

6. Refittheheelguardtighteningthefixingsto

9Nm.

1. Heelguard

2. Fixings