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2. Install the master cylinder assembly on the handlebar
engaging the alignment stud in the hole in the han-
dlebar; then secure with the master cylinder clamp
and two cap screws. Make sure the UP arrow on the
clamp is directed upward.
KM800B
3. Tighten the cap screw (1) to 9 ft-lb; then tighten the
cap screw (2) to 9 ft-lb.
KM800B
4. Using new crush washers, secure the brake hose to
the master cylinder with the brake hose union bolt.
Tighten to 24 ft-lb.
KM800A
5. Fill the master cylinder with DOT 4 brake fluid; then
bleed the system.
Troubleshooting Drive
System
Problem: Braking Poor
Condition
Remedy
1.
Pad
worn
2.
Brake fluid
leaking
3.
Hydraulic system
entrapped air
4.
Master cylinder/brake cylinder
seal worn
1. Replace pads
2. Repair - replace hydraulic system
3. Bleed hydraulic system
4. Replace appropriate cylinder
Problem: Brake lever travel excessive
Condition
Remedy
1.
Hydraulic system
entrapped air
2.
Brake fluid
low
3.
Brake fluid
incorrect
4.
Piston seal - cup
worn
1. Bleed hydraulic system
2. Add fluid to proper level/bleed system
3. Replace with correct fluid
4. Replace master cylinder
Problem: Brake fluid leaking
Condition
Remedy
1.
Connection joints
loose
2.
Hose
cracked
3.
Piston seal
worn
1. Tighten joint
2. Replace hose
3. Replace master/brake cylinder
