Removing the Master Cylinder
Warning: Do not allow brake fluid to come into contact with painted surfaces. You need to wash it off immediately.
1. Remove the brake fluid with a syringe.
2. Remove the first duct.
3. Remove the steering column assembly.
4. Disconnect two brake pipes from the master cylinder.
5. Turn off nuts of fastening of a support and the main brake cylinder, remove them together.
6. Using pliers, disconnect the two reservoir hoses from the brake master cylinder.
Removing the master cylinder.
1 - Master brake cylinder,
2 - Caliper,
3 - Brake pipe,
4 - Lower cover of the steering column,
5 - First air duct,
6 - Steering column assembly,
7 - Top cover of the steering column,
8 - tank hose,
9 - Tank.
Master brake cylinder.
1 - Bypass bolt,
2 - Gasket,
3 - Fitting,
4 - Spring,
5 - Check valve,
6 - External plug,
7 - Piston No. 2,
8 - Piston No. 1,
9 - Retaining ring,
10 - Stop bolt,
11 - Cylinder.
Master cylinder disassembly
1. Clamp the cylinder in a vise.
2. Turn away a bypass bolt, remove the union and linings.
3. Unscrew the outer plug, remove the check valve, spring and gasket.
4. Using a screwdriver, push the pistons all the way, then remove the piston stop bolt and gasket.
5. Take out two pistons with springs.
A) Press the piston with a screwdriver and remove the circlip using round nose pliers.
b) Remove the first piston with the spring by hand, pulling them out without distortion.
Warning: Cylinder damage may occur when pulling at an angle.
V) Putting a rag and two wooden blocks on the workbench, lightly tap the cylinder flange on the bars, then remove the piston by hand.
Inspection of Master Cylinder Components
Note: Clean the disassembled parts by blowing them with compressed air.
1. Check the cylinder bore for rust or nicks.
2. Check the cylinder for wear or damage.
If necessary, clean or replace the cylinder.
Master cylinder assembly
1. Apply lithium based grease as shown.
2. Insert two pistons with springs.
Warning: be careful not to damage the rubber lips of the pistons.
A) Insert two pistons with springs into the master cylinder body.
Warning: Inserting at an angle may damage the cylinder face.
b) After pushing the pistons with a screwdriver, install the snap ring.
3. After pushing the pistons with a screwdriver to the end, screw in the piston lock bolt, after putting a new seal on the bolt.
- Tightening torque - 10 Nm
4. Installation of check valve and external plug.
A) Insert the check valve and spring into the outer plug.
Note: If the machine has front disc brakes, the valve and spring are in the outer plug.
b) Install the outer plug along with a new gasket on the cylinder and tighten it.
Torque:
- DYNA 150 - 67 Nm
DYNA 100:
- Front disc brakes - 44 Nm
- Front drum brakes - 67 Nm
5. Install the fitting, new gaskets and tighten the bypass bolt.
- Tightening torque: 54 Nm
Note: Install the fitting in the direction shown in the figure.
Scheme of installation of fittings.
Scheme of installation of fittings.
Master cylinder installation
1. Adjust the brake booster rod length before installing the master cylinder.
2. Install the master cylinder and caliper.
A) Using pliers, connect two hoses from the reservoir to the brake master cylinder.
b) Install the cylinder and caliper, tighten them with four nuts.
- Tightening torque: 13 Nm
V) Tighten the bolt securing the upper part of the caliper.
Vacuum brake booster.
1 - Vacuum brake booster,
2 - Hose from the tank,
3 - Caliper,
4 - Top cover of the steering column,
5 - Lower cover of the steering column,
6 - First air duct,
7 - Steering column assembly,
8 - Brake pipe,
9 - Master cylinder,
10 - Pin,
11 - Cotter pin.
AISIN Single Chamber Vacuum Intensifier / JKC Single Chamber Vacuum Intensifier
1 - Lock nut,
2 - Separator,
3 - Body seal,
4 - Back of the body,
5 - Diaphragm,
6 - Amplifier piston,
7 - Air filter,
8 - Cover,
9 - Earring,
10 - Valve body,
11 - Reactive disk,
12, 19 - Ring with protrusions,
13 - Body seals,
14 - Front of the body,
15 - Stock,
16 - Diaphragm spring,
17 - Lock pin,
18 - Drive rod,
20 - Diaphragm plate,
21 - Felt sleeve,
22 - Spacer.
3. Connect two brake pipes.
- Tightening torque: 15 Nm
4. Install the steering column assembly.
5. Install the first duct.
6. Fill the reservoir with brake fluid and bleed the brake system.
7. Check for brake fluid leaks.
8. Check and adjust the brake pedal.