Triumph Tiger Explorer XR 2016, Service Manual

Page: 495 / 750

Clip 1.
Clevis pin 2.
Brake hose 3.
Sealing washers 4.
Fixings 5.
Master cylinder 6.
Reservoir bracket 7.
Disconnect the reservoir hose from the master cylinder. 7.
Rear Master Cylinder - Inspection
Remove the boot from the cylinder and pushrod. 1.
Remove the circlip retaining the pushrod to the cylinder. Discard the circlip. 2.
Remove the pushrod and piston set from the master cylinder bore, noting the relative position of the seals
and piston components. 3.
Rear Master Cylinder - Assembly
Visually inspect the master cylinder bore for wear, scratches or corrosion. Replace as necessary. 1.
Check the piston and cylinder bore for damage, wear or deterioration. Replace as necessary. 2.
Always renew the piston and seal set if the cylinder is dismantled. 3.
Examine the pushrod for bends and damage. Replace as necessary. 4.
Rear Master Cylinder - Installation
WARNING
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 efficiency resulting in loss of
motorcycle control and an accident.
WARNING
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.
Clean the master cylinder bore, piston and seals, with new brake fluid. 1.
Ensure all ports are clear of obstruction. 2.
WARNING
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.
Install the spring and piston set together. 3.
Tiger Explorer XR Series
491 of 746
BRAKES