Service manual

BRAKES
MASTER CYLINDER INSTALLATION
1. Install master cylinder on handlebars. Torque mounting
bolts to 3 Nm (25 in. lbs.). Torque the top bolt first.
NOTE: To speed up the brake bleeding procedure the
master cylinder can be purged of air before brake line is
attached. Fill with DOT4 Brake Fluid and pump lever
slowly two to three times with finger over the outlet end to
purge master cylinder of air.
2. Place new sealing washers on each side of banjo
brake line. Install the brake line into the master cylinder.
Torque the banjo bolt to 20 Nm (15 ft.lbs.).
Master Cylinder Mounting Clamp
Bolt Torque: 3 Nm (25 in. lbs.)
Banjo Bolt Torque:
20 Nm (15 ft. lbs.)
3. Fill reservoir with DOT4 Brake Fluid.
4. Follow bleeding procedure on Pages 8.8.
Check all connections for leaks and repair if necessary.
FRONT PADS REMOVAL
1. Follow front caliper remove procedure on page 8.6.
Severe injury could occur if machine tips or falls.
2. With pads remove, push caliper piston into caliper bore
slowly using a C-clamp or locking pliers.
NOTE: Brake fluid will be forced through compensating
port into master cylinder fluid reservoir when piston is
pushed back into caliper. Remove excess fluid from
reservoir as required.
8.11