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7
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Take the master cylinder assembly in the left
hand (having assembled up to the point as described
above) supporting the casting with the first and
second fingers under the switch boss (hose and
pressure switch threaded bores pointing downwards)
and left thumb on the top of the casting close to
the piston thrust "pad." Apply a gentle rotary
action with the right hand to the piston thrust
pad, at the same time maintaining downward thrust
pressure against the trap valve spring assembly -
ensuring the lip of the secondary cup enters the
cylinder bore freely and without damage to the lip.
When the piston has entered the bore, move the left
thumb over to maintain the piston within the bore,
at the same time using a blunt prod to snug the
lower boot shoulder into the cylinder counter bore.
Once this is seen to be achieved, and still
maintaining pressure on the piston thrust pad, work
the boot retaining circlip down to locate and
restrain the boot in position. Still maintaining
pressure on the piston thrust pad with the left
humb, slide the brake lever into position at the
fulcrum slot, engaging the thrust pad close to the
operator's left thumb. By holding the lever knob
against the chest, alignment of the holes can be
achieved, and the pivot bolt slid into position,
and located with the locknut.
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Master Cylinder Refitting
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Refitting the master cylinder is the exact
reverse procedure of the dismantling sequence
described above. Refit the master cylinder to the
handlebar, the oil pressure switch and brake hose.
Slide the plastic switch cover over the hose, hold
in a convenient location whilst the brake light
wires are connected to the brake switch terminals
and slide the cover into final location. Enter the
lower hose into the fork support bracket, locate in
position with the locknut and tighten up the upper
brake pipe union nut. Bleed the hydraulic system as
described in the following text, after ensuring
that the master cylinder is level on the handlebar.
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Bleeding the Hydraulic Brake System
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1
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Remove the reservoir cap and fill the reservoir
almost to the top. Remember that brake fluid ruins
paintwork and do not allow fluid to spill during
filling.
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2
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Connect a small bore rubber tube from the
caliper bleed screw to a clean jar or receptacle.
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3
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Unscrew the bleed screw one full turn and start
to pump slowly the handlebar lever. As fluid is
forced to the caliper and through the bleed nipple,
the master cylinder level will drop. Take care
throughout the operation that the level does not
drop sufficiently low to allow further air to be
pumped into the system and top up where necessary.
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4
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Continue pumping the lever until fluid free of
air bubbles exits from the bleed tube into the
fluid container then hold the brake lever "on"
against the handlebar whilst the caliper bleed
screw is tightened and the bleed tube removed.
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5
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Test the brake for "sponginess." If the action
feels "spongy," then air remains in the system and
further bleeding must be undertaken.
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6
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Ensure that the master cylinder reservoir is
brought to the correct level then refit the bellows
seal and cap.
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7
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Finally check all unions for security and
freedom from leaks.
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