Service Manual

11.7
BRAKES
11
9. Repeat the procedure on the two remaining front calipers.
10. Add DOT 4 brake fluid to .25” - .30” (6 - 8 mm) from the
top of the reservoir.
11. Install diaphragm, cover and screws. Torque the screws to
7 in. lbs. (0.8 Nm).
12. Proceed to “Rear Brake System Bleeding” to complete
bleeding procedure.
Rear Brake System Bleeding
Remove the front rack and locate the foot brake fluid reservoir
for the foot master cylinder (see the following illustration).
1. Thoroughly clean the fluid reservoir cover before removal.
2. Remove the cap and diaphragm from the reservoir and
verify fluid level is at the MAX level mark.
3. If changing fluid, remove old fluid from reservoir with a
Mity Vac™ (PN 2870975) or similar tool.
4. Using a funnel, add brake fluid to the MAX level mark on
the reservoir.
5. Install a box end wrench on the rear caliper bleeder screw.
Attach a clean, clear hose to fitting and place the other end
in a container. Be sure the hose fits tightly on fitting.
6. Slowly pump the foot brake pedal until pressure builds and
holds.
7. While maintaining pedal pressure, open bleeder screw.
8. Close bleeder screw and release brake pedal.
NOTE: Do not release pedal before bleeder screw is
tight or air may be drawn into caliper.
9. Repeat procedure until clean fluid appears in bleeder hose
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
10. Tighten bleeder screw securely and remove bleeder hose.
Torque the bleeder screw to 47 in. lbs. (5.3 Nm).
11. Repeat the procedure on the remaining rear caliper.
12. Using a funnel, add brake fluid to the MAX level mark on
the reservoir.
13. 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 1/
2”, (1.3 cm) from handlebar.
14. Check brake system for fluid leaks and inspect all hoses and
lines for wear or abrasion. Replace hose if wear or abrasion
is found.
7 in. lbs.
(0.8 Nm)
Hand Master Cylinder