Triumph 2010 Tiger 800, Service Manual

Page: 385 / 508

10. Disconnect the reservoir hose and remove the
master cylinder.
Disassembly
1. Remove the boot from the cylinder and pushrod.
2. Remove the circlip retaining the pushrod to the
cylinder.
3. Remove the pushrod and piston set from the master
cylinder bore, noting the relative position of the seals
and piston components.
Inspection
1. Visually inspect the master cylinder bore for wear,
scratches or corrosion. Replace as necessary.
2. Check the piston and cylinder bore for damage,
wear or deterioration. Replace as necessary.
3. Always renew the piston and seal set if the cylinder is
dismantled.
4. Examine the pushrod for bends and damage.
Replace as necessary.
Assembly
Never use mineral based grease <such as lithium or
copper based grease> in any area where contact with the
braking system hydraulic seals and dust seals is possible.
Mineral based grease will damage the hydraulic seals
and dust seals in the calipers and master cylinders.
Damage caused by contact with mineral based grease
may reduce braking
resulting in an accident.
Before installation, all internal brake components should
be cleaned and lubricated with clean new DOT 4 brake
fluid.
Never use solvents, petrol (gasoline>, engine oil, or any
other petroleum distillate on internal brake components
as this will cause deterioration of the hydraulic seals in
the calipers and master cylinders.
A dangerous riding condition leading to loss of
motorcycle control and an accident could result if this
warning is ignored.
Brakes
1. Clean the master cylinder bore, piston and seals, with
new brake fluid.
2. Ensure all ports are clear of obstruction.
I
•
"
Ensure that the piston and piston seal are fitted facing
the same way as noted during removal. A dangerous
riding condition leading to an accident could result from
incorrect assembly of the master cylinder.
3. Install the spring and piston set together.
4. Apply a small amount of brake grease to the
push rod.
5. Install the pushrod in the master cylinder and retain
with a new circlip.
6. Refit the boot.
cdlu1
1. ReseNoir hose
2. Piston set
3. Dust boot
4. Push rod
5. Clevis pin
6. Ciip
7. Circlip
Service Manual
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Tiger 800 and Tiger 800XC
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