Honda TRANSALP XL600-650V (1987-2002) [202/291] Brakes wheels and tyres 7 17
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Honda TRANSALP XL600-650V (1987-2002) [202/291] Brakes wheels and tyres 7 17

Honda TRANSALP XL600-650V (1987-2002) [202/291] Brakes wheels and tyres 7 17

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Brakes wheels and tyres 7 17 9 Dislodge the rubber dust boot from the base of the master cylinder and from around the pushrod noting how it locates and slide it up the pushrod 10 Push the pushrod in and using circlip pliers remove the circlip from its groove in the master cylinder and slide out the piston assembly and the spring noting how they fit If they are difficult to remove apply low pressure compressed air to the fluid outlet Lay the parts out in the proper order to prevent confusion during reassembly 11 If required remove the screw securing the fluid reservoir hose union and detach it from the master cylinder Discard the O ring as a new one must be used Inspect the reservoir hose for cracks or splits and replace with a new one if necessary 12 Clean all of the parts with clean brake fluid or denatured alcohol Caution Do not under any circumstances use a petroleum based solvent to clean brake parts If compressed air is available use it to dry the parts thoroughly make sure it s filtered and unlubricated 13 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 If the master cylinder is in poor condition then the caliper should be checked as well 14 The dust boot circlip piston seal cup and spring are included in the rebuild kit Use all of the new parts regardless of the apparent condition of the old ones If the seal is not already on the piston fit it according to the layout of the old one Slide the new boot onto the pushrod making sure it is the correct way round 15 Fit the cup over the end of the spring so that its inner raised section tits into the outer coil on the spring Lubricate the cup seal and piston with clean brake fluid 16 Install the spring in the master cylinder with the cup facing out then fit the piston into Ihe master cylinder making sure it is the correct way round Make sure the lips on the cup and seal do not turn inside out when they enter the bore 17 Apply some silicone grease to the end of the pushrod and fit it into the master cylinder Depress the pushrod then install the new circlip making sure it is properly seated in the groove 18 Install the rubber dust boot making sure it is seated properly In the groove in the master cylinder and around the pushrod 19 If removed fit a new O ring to the fluid reservoir hose union then fit the union onto the master cylinder and secure it with its screw 20 If removed thread the clevis locknut and the clevis onto the master cylinder pushrod end Set the clevis position as noted on 8 8 Rear master cylinder components 1 Reservoir hose union 2 O ring 3 Master cylinder 4 Spring 5 Cup 11 Pushrod 12 Roll pin 13 Brake pedal arm 14 Clevis pin 15 Clevis 16 Split pin 6 Piston 7 Seal 3 Nut 9 Circlip 10 Rubber boot removal Honda specify the distance between the eye in the clevis and the lower mounting bolt hole should be 100 mm Tighten the clevis locknut securely against the clevis 21 Where the clevis is retained by a roll pin secure it in position with a new pin Installation 22 Fit the master cylinder onto the footrest bracket and tighten its mounting bolts to the torque setting specified at the beginning of the Chapter see illustration 8 4c 23 Align the brake pedal with the master cylinder pushrod clevis then slide in the clevis pin and secure it using a new split pin see illustrations 8 6b and a 24 Connect the brake hose to the master cylinder using new sealing washers on each side of the union Align the hose as noted on removal and tighten the banjo bolt to the specified torque setting see illustration 8 5 25 Fit the fluid reservoir on its mount and secure it with its bolt see illustration 8 4a or b Ensure that the hose is correctly routed then connect it to the union on the master cylinder and secure it with the clamp see illustration 8 4c Check that the hose is secure and clamped at the reservoir end as well If the clamps have weakened use new ones 26 Fill the fluid reservoir with new DOT 4 brake fluid see Daily pre ride checks and bleed the system following the procedure in Section 10 27 Check the operation of the brake and brake light carefully before riding the motorcycle 28 On XRV750 L to N 1990 to 1992 models install the right hand passenger footrest bracket and tighten its bolts securely Install the right hand side panel see Chapter 8 9 Brake hoses and unions inspection and replacement Inspection 1 Brake hose and pipe condition should be checked regularly see Chapter 1 2 Twist and flex the rubber hoses while looking for cracks bulges and seeping fluid see illustration Check extra carefully around the areas where the hoses connect with the banjo fittings as these are common areas for hose failure 3 Inspect the metal brake pipes and the banjo union fittings connected to the brake hoses If the fittings are rusted scratched or cracked replace them with new ones 7

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