Rear 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

Rear Master Cyl Remove - LG1; LGX

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.
note
The brake caliper will require removing and the pistons pushed out to back bleed the master cylinder as part of the brake bleeding procedure, see Bleeding the Rear Brakes.

Perform the following operations

Perform the following operations:

Rear Wheel - Remove L Series

    warning
    Make sure no damage is made to the brake pad material when moving the brake pads.Allowing the brake pads to come into contact with each other or sharp objects may cause the material to crack or break.Damage to the brake pads may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
  1. 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 rear brake pedal slowly until the plate is held by the brake pads. Do not allow the pistons to fall out.
    2. caution
    When disconnecting the brake hose from the master cylinder it is necessary to keep the open end of the hose above the height of the rear brake master cylinder.Allowing the brake hose to fall below the rear brake master cylinder 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.
  2. Noting its orientation for installation, disconnect the brake hose from the master cylinder, discard the washers and allow the brake fluid to drain from the master cylinder outlet into a suitable container.
  3. Remove and discard the rear master cylinder reservoir fixing and support the reservoir.
  4. Remove the two fixings and remove the right hand control plate and rear brake master cylinder assembly.
    5. note
    Note the routing of the rear brake switch harness for installation.
  5. Disconnect the rear brake switch from the main harness.
  6. Remove the two fixings and remove the rear brake switch and bracket from the control plate, noting the routing for installation. Position the brake switch and bracket to one side.
    7. Rear brake master cylinder and control plate_1 (ckxk)

    1. Fixings

    2. Rear brake switch bracket

    note
    Note the position and orientation of the clevis pin and clip for installation.
  7. Remove the clip and clevis pin at the lower end of the brake push rod.
  8. Remove the two fixings and remove the master cylinder from the control plate.
    9. Rear brake master cylinder and control plate_2_1 (ckxl)

    1. Fixings

    2. Clevis pin

    3. Clip

  9. Disconnect the reservoir hose from the master cylinder if required and collect any brake fluid.