Service manual

BRAKES
12. Add brake fluid to the proper level.
Master Cylinder Fluid Level:
MAX level inside reservoir
Sight glass must look dark, if sight
glass is clear, fluid level is too low
13. Install diaphragm, cover, and screws.
14. Field test machine at low speed before putting into
service. Check for proper braking action and lever
reserve. With lever firmly applied, lever
reserve should be no less than 2 cm from handlebar.
15. Check brake system for fluid leaks and inspect all
hoses and lines for wear or abrasion. Replace hose if
wear or abrasion is found.
NOTE:
1. Check the fluid lever often while bleeding the brake to
prevent air from being pumped into the system.
2. Repeat the above procedure until air bubbles do not
appear in the plastic hose.
3. If air is entering the bleeder from around the bleed
valve threads, seal the threads with Teflon tape.
4. Close the bleed valve and operate brake lever. If it still
feels spongy, bleed the system again.
5. If a brake bleeder is not available, use the following
procedure:
Pump up the system pressure with the brake lever until
lever resistance is felt.
MASTER CYLINDER REMOVAL
1. Clean master cylinder and reservoir assembly. Make
sure you have a clean work area to disassemble brake
components.
2. Place a shop towel under brake line connection at
master cylinder. Loosen banjo bolt; remove bolt and
sealing washers.
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
3. Loosen the master cylinder clamp bolts on the
handlebar side of the master cylinder.
4. Remove master cylinder from handlebars.
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