76
ATV2189
4. Coat the axle threads with red Loctite #271 and
install one axle nut; then using the Rear Axle Nut
Wrench, tighten the inner axle nut to calculated spec-
ification.
TR235
NOTE: Compress the left hand brake and engage the
brake lever lock to prevent the rear axle from turning
5. Install the outer axle nut and tighten to calculated speci-
fication.
6. Adjust the drive chain (see Periodic Maintenance/Tune-
Up); then tighten the two cap screws and adjuster nut.
7. Install the wheel hubs and tighten the rear wheel hub
nuts to 50 ft-lb; then install the cotter pins and hub caps.
8. Install the rear wheels and tighten to 30 ft-lb.
Rear Brake Lever/Master
Cylinder Assembly
NOTE: The master cylinder is a non-serviceable
component; it must be replaced as an assembly.
REMOVING
1. Connect a clear hose to the bleed screw on the rear
brake caliper; then open the bleed screw and pump
the brake fluid into a suitable container. Close the
bleed screw.
TR031A
NOTE: Do not reuse brake fluid. When exposed to
air, brake fluid rapidly absorbs moisture.
2. Remove the brakeline hose union bolt; then remove
the cap screws securing the master cylinder assembly
to the handlebar. Discard the crush washers from the
union bolt.
KM800A
3. Remove the brake lever, brakelight switch, and brake
lever lock.
INSPECTING
1. Inspect the pivot bolt securing the brake lever for
wear.
2. Inspect the brake lever for elongation of the pivot
hole.
3. Inspect the reservoir for cracks and leakage.
4. Inspect the brake hose for cracks and deterioration
and the condition of the fittings (threaded and com-
pression).
5. Inspect the brakelight switch for corrosion, cracks,
missing or broken mounting tabs, or broken and
frayed wiring.
NOTE: If the brakelight switch is determined to be
not serviceable, see Taillight/Brakelight.
INSTALLING
1. Install the brakelight switch on the master cylinder;
then install the brake lever and brake lever lock.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV.
