6
Bleeding the Hydraulic Brake System
BRAKES
Master Cylinder Installation
1.
Install master cylinder in reverse order of removal. Tighten locknuts to 168 in-lb (19 N·m). Tighten the front
and rear brake hose fittings to 146 in-lb (16.5 N·m)
2.
Check brake pedal adjustment.
See Brake Pedal Adjustment, Section 5, Page 5-15.
3.
Fill the reservoir of the master cylinder and bleed the hydraulic brake system.
4.
Perform all of the brake system inspections.
See Brake System Inspection on page 6-4.
BLEEDING THE HYDRAULIC BRAKE SYSTEM
See General Warning on page 1-2.
WARNING
• Do not bleed the brakes in the same manner as a DOT 3 system. Failure to bleed the brakes as
instructed in this manual will result in decreased braking performance due to air being trapped in
the hydraulic system.
• Use only DOT 5 brake fluid to fill the master cylinder. NEVER mix DOT 3, DOT 4, or DOT 5.1 with
DOT 5 as it IS NOT compatible.
The hydraulic system must be free of air. Air enters the hydraulic system whenever the system is opened and will
result in a “spongy” brake pedal.
The master cylinder controls two separate hydraulic sub-systems. The front two wheels are connected to the front
portion of the master cylinder and the rear wheels to the rear portion. One or both sub-systems may require bleeding,
depending on where the hydraulic system was opened.
Vacuum bleeding is the recommended way to remove air from a brake system filled with DOT 5 silicone brake fluid. If a
vacuum brake bleeding tool is not available, manually bleeding the system can be accomplished when done carefully.
VACUUM BLEEDING OF BRAKES ON A DOT 5 FLUID FILLED SYSTEM
1.
Turn the key switch OFF and remove the key. Place the Forward/Reverse switch in NEUTRAL.
2.
Check the brake pedal and master cylinder push rod for proper adjustment before the brake system is bled.
Brake Pedal Adjustment, Section 5, Page 5-15.
3.
Remove the cap from the master cylinder reservoir and top off the master cylinder with fresh DOT 5 silicone brake
fluid.
NEVER
mix DOT 3, DOT 4, or DOT 5.1 with DOT 5 as it
IS NOT
compatible.
4.
Place, but do not tighten, the cap on the master cylinder reservoir.
5.
Chock the front or rear wheels and loosen the lug nuts. Release the park brake and lift the front or rear of the
vehicle with a chain hoist or floor jack.
See WARNING “Lift only one end...” in General Warning on page 1-2.
6.
Place jack stands under the frame and lower onto stands.
See Lifting The Vehicle, Section 3, Page 3-4.
7.
Connect the vacuum-type brake bleeder (CC P/N S0010702).
7.1.
Front Brakes Only:
Connect the two hose fittings from a vacuum type brake bleeder to the top brake
bleeder valves on the back of each of the front caliper assemblies.
7.2.
Rear Brakes Only:
Connect the two hose fittings from a vacuum type brake bleeder to the top brake
bleeder valves on the back of each of the rear caliper assemblies.
Page 6-16
2009-2012 XRT 950 Maintenance and Service Manual
