See Figure 2-40. Do not install the master cylinder assembly without first placing the 4 mm (5/32 in.) thick cardboard insert (or cable strap eyelet) between the brake lever and lever bracket. Installation without the insert may result in damage to the rubber boot and plunger of the front stoplight switch.

1. See Figure 2-41. Position brake lever/master cylinder assembly inboard of switch housing assembly engaging tab (2) on lower switch housing (1) in groove (3) at top of brake lever bracket (4).

2. Align holes in handlebar clamp with those in master cylinder housing and start both screws with flat washers. Position for rider posture. Beginning with top screw, tighten to 38-72Nm (28-53 ft-lbs).


To avoid leakage, verify that the steel/rubber washers, banjo bolt, brake line fitting and master cylinder bore are completely clean.

3. Lubricate new steel/rubber washers with D.O.T. 5 SILICONE BRAKE FLUID. Position new steel/rubber washers on each side of hydraulic brake line fitting. Insert bolt through washers and fitting. Thread banjo bolt into master cylinder housing and tighten to 23-31 Nm (17-22 ft-lbs).

4. Install length of clear plastic tubing over caliper bleeder valve, if removed. Place free end of tube in a clean container.

5. Stand the motorcycle upright so that master cylinder is level. Remove master cylinder cover.


Direct contact of D.O.T. 5 brake fluid with eyes may cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid may cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.

6. Add D.O.T. 5 SILICONE BRAKE FLUID to master cylinder reservoir until fluid level is 1/8 inch (3.2 mm) from top. Do not reuse old brake fluid. Use only D.O.T. 5 SILICONE BRAKE FLUID from a sealed container.

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

Don't pay hundreds of dollars to find out what is wrong with your car. This book is dedicated to helping the do it yourself home and independent technician understand and use OBD-II technology to diagnose and repair their own vehicles.

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