Honda TRANSALP XL600-650V (1987-2002) [200/291] Brakes wheels and tyres 7 15
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Honda TRANSALP XL600-650V (1987-2002) [200/291] Brakes wheels and tyres 7 15

Honda TRANSALP XL600-650V (1987-2002) [200/291] Brakes wheels and tyres 7 15

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Brakes wheels and tyres 7 15 7 11 Front master cylinder components 1 Hand guard 2 Collar 3 Trunnion 4 Brake lever 5 Span adjuster 6 Spring 7 Adjuster wheel 8 Adjuster thread 9 Pivot 10 Rubber boot 11 Circlip 12 Seal 13 Piston 14 Cup 15 Spring 16 Lever pivot bolt 17 Reservoir cover use a petroleum based solvent to clean brake parts 14 Check the master cylinder bore for corrosion scratches nicks and score marks If the necessary measuring equipment is available compare the dimensions of the piston and bore to those given in the Specifications Section of this Chapter If damage or wear is evident the master cylinder must be replaced with a new one It the master cylinder is in poor condition then Overhaul the calipers should be checked as well Check 11 Carefully remove the dust boot from the that the fluid Inlet and outlet ports in the master cylinder are clear end of the master cylinder and from around 15 The dust boot circlip piston seal cup the piston noting how it locates see and spring are included in the rebuild kit Use illustration 12 Push the piston in and using circlip pliers all of the new parts regardless of the remove the circlip from its groove in the apparent condition of the old ones If the seal and cup are not already on the piston fit them master cylinder and slide out the piston according to the layout of the old one assembly and the spring noting how they fit If they are difficult to remove apply low 16 Lubricate the cup seal and piston with clean brake fluid pressure compressed air to the fluid outlet Lay the parts out in order as you remove them 17 Fit the spring into the piston so that its narrow end points out then fit the piston into to prevent confusion during reassembly 13 Clean all parts with clean brake fluid or the master cylinder making sure it is the denatured alcohol If compressed air is correct way round and that it locates correctly available use it to dry the parts thoroughly against the spring Make sure the lips on the cup and seal do not turn inside out when they make sure It s filtered and unlubricated enter the bore Depress the piston and install Caution Do not under any circumstances Caution Do not tip the master cylinder upside down or brake fluid will run out 9 Remove the reservoir cover diaphragm plate and rubber diaphragm Drain the brake fluid from the reservoir Into a suitable container Wipe any remaining fluid out of the reservoir with a clean rag 10 If required undo the brake light switch screw and remove the switch noting how it fits 18 Plate 19 Diaphragm 20 Separator 21 Brake light switch 22 Nut the new circlip making sure that it locates in the groove in the master cylinder 18 Apply some silicone grease to the inside of the rubber dust boot then install it making sure it is seated properly In the groove in the master cylinder and around the piston 19 Inspect the reservoir rubber diaphragm and renew it if it is damaged or deteriorated Installation 20 Locate the brake light switch on the underside of the master cylinder and secure it with the screw 21 Attach the master cylinder to the handlebar and fit the clamp with its UP mark facing up see illustration Align the top mating surfaces of the clamp with the punch mark on the top of the handlebar then tighten the top bolt first then the bottom bolt to the torque setting specified at the beginning of the Chapter 22 On XL600V M to X 1991 to 1999 models 7 and XL650V models connect the brake hose to the master cylinder using new sealing washers on each side of the union and aligning the hose as noted on removal see illustration 7 6 Tighten the banjo bolt to the torque setting specified at the beginning of the Chapter

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