Front Brake Master Cylinder - Removal

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.

Perform the following operations

Perform the following operations:

Seat - Remove L Series

Battery - Remove L Series

Caution - Do not spill brake fluid

caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.

Front Master Cyl Remove - LG1; LGX

  1. Note the setting of the brake lever adjuster to make sure it is returned to the same position when the overhaul operation is complete.
    2. note
    One of the brake calipers will require removing and the pistons pushed out to back bleed the master cylinder as part of the brake bleeding procedure, see Bleeding the Front Brakes.
  2. Remove the caliper mounting bolts and slide the caliper off the brake disc.
    3. Front brake caliper mounting bolts (ckwv)

    1. Caliper mounting bolts

    2. Brake pad retaining pin

  3. Using a suitable flat metal plate approximately 2 mm thick and 30 to 50 mm wide (for example a gasket scraper) between the brake pads, pump the front brake lever slowly until the plate is held by the brake pads. Do not allow the pistons to fall out.
    4. caution
    When disconnecting the brake hose from the master cylinder it is necessary to keep the open end of the hose above the handlebars.Allowing the brake hose to fall below the handlebar height will allow an excessive amount of air to enter into the brake system. Trapped air may cause the brake lever to feel spongy and contribute to reduced braking efficiency.
  4. Noting its orientation for installation, disconnect the brake hose, discard the washers and allow the brake fluid to drain from the master cylinder outlet into a suitable container.
    5. note
    Note the position of the brake light switch and bracket for installation.
  5. Release the fixing and remove the brake light switch and bracket.
    6. Front brake switch and bracket, L0378

    1. Brake light switch

    2. Bracket

    3. Fixing

  6. Remove the pivot lock nut and bolt securing the brake lever to the master cylinder, and remove the lever.
  7. Release the clamp screws from the handlebar to remove the master cylinder.