Note

On 1972 and earlier models with drum brake, make sure to order parts 41773-58 (valve and seat) and install them in the order shown in 19(G, H), Figure 32 or 12(G, H), Figure 33.

12. Install the stop wire in the end of the master cylinder housing. Make sure the wire seats in the groove.

13. Install the rubber boot and plunger.

14. Reconnect the clevis pin.

15. Bleed the rear brake as described in this chapter.

16. Adjust the rear brake as described in Chapter Three.

Overhaul (Late 1979-on FLand Late 1979-on FX Except 1983-1984 FXWG)

Refer to Figure 34 (FL), Figure 35 (FX except FXWG) or Figure 36 (1980-1982 FXWG).

1. Remove the master cylinder assembly as described in this chapter.

2. Remove the cover and gasket. Drain and discard the brake fluid from the master cylinder.

3. Pull the rubber boot off the end of the master cylinder and remove the retaining ring. Then remove the piston assembly in the order shown in Figure 34, Figure 35 or Figure 36.

WARNING The 1984 FL models do not use the backup disc (37D, Figure 34) because of a design change to the master cylinder piston. Use of the backup disc on these models may cause brake drag or brake lockup.

4. Remove the O-ring from the piston.

5. Carefully inspect the O-ring, cup and dust boot for softening or wear. Replace these parts whenever the master cylinder is disassembled.

6. Inspect the master cylinder walls for scratches or wear grooves. The master cylinder housing should be replaced if the cylinder walls are damaged. Do not hone the cylinder walls.

7. Check to see that the vent hole in the cover is not plugged.

8. Check the plunger assembly for wear, bending or damage. Replace it if necessary.

9. Coat all internal parts in specified brake fluid before assembly.

10A. Referring to Figure 34, install the following parts in order: a. Spring (37G).

REAR BRAKE MASTER CYLINDER (LATE 1979-ON FX EXCEPT FXWG)

(LATE 1979-1983 EXCEPT FXWG AND FXSB)

(LATE 1979-1983 EXCEPT FXWG AND FXSB)

1. Brake hose

2. Bolt

3. Lockwasher

4. Plate

5. Screw

6. Cover

7. Diaphragm

8. Master cylinder housing

9. Rubber boot

10. Brake rod

11. Piston assembly

12. Screw

13. Cover

14. Diaphragm

15. Master cylinder housing

16. Plate

17. Bolt

18. Brake hose

19. Bolt

20. Clip

21. Brake hose

22. Junction block (all models)

23. Plate

24. Lockwasher

25. Nut

26. Stoplight switch (all models)

27. Piston assembly (1983-on FXSB; 1984 FXE)

28. Clip

29. Bleed scew

30. Bracket

31. Spacer

32. Mounting plate

33. Brake hose

34. Bolt

35. Washer

36. Master cylinder housing

37. Rubber boot

38. Brake rod

39. Nut

40. Clevis pin

41. Brake rod clevis

42. Bushing

43. Brake pedal

44. Spring

45. Plain washer

46. Bracket

47. Washer

48. Cotter pin

49. Brake pedal rubber b. Spring seat (37F).

WARNING The backup disc (37D, Figure 34) is not used on 1984 FL models. Installation of the disc on this model may cause brake drag or brake lockup.

f. Insert the piston assembly into the master cylinder. Install the circlip (A) in the end of the master cylinder housing.

10B. Internal reservoir models: Referring to Figure 35. install the following parts in order:

e. Insert the piston assembly into the master cylinder. Install the circlip (11 A) in the end of the master cylinder housing.

10C. Separate reservoir models: Referring to Figure 35, install the following parts in order:

e. Install the seal (27C) on the piston (27B). Insert the piston assembly into the master cylinder. Install the circlip (27A) in the end of the master cylinder housing.

10D. Referring to Figure 36, install the following parts in order:

e. Insert the piston assembly into the master cylinder. Install the circlip (A) in the end of the master cylinder housing.

11. Install the boot onto the master cylinder.

12. Install the master cylinder as described in this chapter.

Overhaul (1983-on FXWG)

Refer to Figure 37 for this procedure. 1. Remove the master cylinder assembly as described in this chapter.

REAR BRAKE MASTER CYLINDER (1980-1982 FXWG)

1. Brake pedal rubber

2. Brake pedal

3. Bolt

4. Spring washer

6. Bolt

7. Plate

8. Lockwasher

10. Brake hose

11. Bolt

12. Stoplight switch

13. Brake hose

14. Junction block

15. Hose pad

16. Bracket

17. Nut

18. Spring

19. Brake lever clevis

20. Bolt

21. Bolt

22. Brake pedal shaft

23. Bearing

24. Screw

25. Brake pedal

26. Cover

27. Bracket assembly

28. Plug

29. Clevis pin

30. Plunger

31. Rubber boot

32. Washer

33. Cotter pin

34. Bolt

35. Piston assembly

36. Screw

37. Cover

38. Diaphragm

39. Nut

40. Spacer

41. Brake hose

42. Master cylinder

® REAR BRAKE MASTER CYLINDER

(1983-ON FXWG)

1. Screw

2. Cover

3. Diaphragm

4. Reservoir

5. Bracket

6. Bolt

7. Clamp

8. Hose

9. Hose fitting

10. Bolt

11. Junction block

12. Hose

13. Stoplight switch

14. Bracket

15. Lockwasher

16. Nut

17. Hose

18. Hose clamp

19. Hose pad

20. Support bracket

21. Lockwasher

22. Bolt

23. Spring washer

24. Bolt

25. Nut

26. Brake pedal

27. Nut

28. Brake pedal

29. Mounting bracket

30. Bolt

31. Nut

32. Nut

33. Piston assembly

34. Master cylinder

35. Bolt

36. Lockwasher

37. Washer

38. Washer

39. Spring

40. Rubber boot

41. Plunger

42. Nut

43. Brake rod clevis

44. Clevis pin

45. Bolt

46. Washer

47. Brake pedal

48. Pedal rubber

49. Nut

50. Cotter pin

51. Plain washer

2. Remove the cover and gasket. Drain and discard the brake fluid from the master cylinder.

3. Pull the rubber boot (40, Figure 37) off the end of the master cylinder and remove the following parts in order:

b. Return washer (early 1983 models only) (38).

c. Return spring washer (37).

d. Retaining ring (33A).

e. Piston assembly (33).

5. Carefully inspect the O-ring, cup and dust boot for softening or wear. Replace these parts each time the master cylinder is disassembled.

6. Inspect the master cylinder walls for scratches or wear grooves. The master cylinder housing should be replaced if the cylinder walls are damaged. Do not hone the cylinder walls.

7. Check to see that the vent hole in the cover is not plugged.

8. Check the plunger (41) on the end of the brake rod clevis (43) for wear, bending or damage. Replace it if necessary.

9. Coat all internal parts in specified brake fluid before assembly.

10. Referring to Figure 37, install the following parts in order:

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