6.4.5 Removal and Installation
6.4.5.1 

Brake 

Master 

Cylinder 

Tank

Replacement

Removal Procedure:

FE06-0031b

1.

Remove the brake master cylinder. Refer to 

6.4.5.2

 

Brake

Master Cylinder Replacement

.

2.

Remove  the  brake  master  cylinder  and  the  tank
connecting  pin.  From  the  brake  master  cylinder  tank
remove and replace the seals.

Installation Procedure:

FE06-0032b

1.

Apply clean brake fluid to lubricate tank seals.

2.

Install the lubricated seal into the brake master cylinder.

3.

Install the tank to the brake master cylinder and install the
connecting pin.

4.

Install the brake master cylinder with the tank.

6.4.5.2 Brake Master Cylinder Replacement

Removal Procedure:

Warning!

Refer to 'Battery Disconnect Warning" in "Warnings and
Notices".

Brake System

Hydraulic Brake

6-37

1

2

3

2

FE06-0033b

1.

Disconnect  the  battery  negative  cable.  Refer  to

2.11.8.1

 

Battery Disconnection

.

2.

Drain the brake fluid.

Note

Refer to "Brake Fluid Effects on Paint and Electrical
Components Notice" in "Warnings and Notices".

3.

Disconnect  the  brake  fluid  level  sensor  wiring  harness
connector (1), and remove the brake pipe connector nut
(2).

4.

Loosen clutch master cylinder to the tank hose clip (3),
and pull the hose from the tank.

FE06-0034b

5.

Plug the brake pipe openings to prevent brake fluid loss
and contamination.

6.

Remove the brake master cylinder retaining nuts.

7.

Remove the brake master cylinder with the tank, place the
brake master cylinder on a clean table.

FE06-0031b

8.

Remove  the  tank  and  the  brake  master  cylinder
connection pin, separate the tank and the brake master
cylinder.

9.

Remove the brake master cylinder.

6-38

Hydraulic Brake

Brake System

Installation Procedure:

FE06-0032b

1.

Install the brake master cylinder to the tank connecting
pin.

FE06-0037b

2.

Install  the  brake  master  cylinder  with  the  tank  into  the
vacuum booster.

3.

Tighten the brake master cylinder retaining nuts.

Torque: 25 Nm (Metric) 18.5 lb-ft (US English)

FE06-0038b

4.

Connect the brake fluid level sensor harness connector,
fix with the clutch master cylinder hose to the tank, tighten
the brake pipe connecting nut.

Torque: 16 Nm (Metric) 11.9 lb-ft (US English)

5.

Add brake fluid.

Note

Refer to "Adding Fluid to the Brake System Notice"
in "Warnings and Notices".

6.

Bleed air in the brake system. Refer to 

6.4.5.5

 

Hydraulic

Brake System Exhaust Procedure

.

7.

Bleed air in the clutch system. Refer to 

3.2.6.3

 

Hydraulic

Clutch Bleeding

.

8.

Check for leaks.

9.

Re-examine the brake fluid.

Brake System

Hydraulic Brake

6-39

10. Connect the battery negative cable.

6.4.5.3 Brake Hose Replacement (Front)

Removal Procedure:

Note

Refer  to  "Brake  Fluid  Effects  on  Paint  and  Electrical
Components Notice" in "Warnings and Notices".

FE06-0039b

1.

Drain the brake fluid.

2.

Lift and support the vehicle. Refer to

1.3

 

Lifting and Jacking

the Vehicle

.

3.

Remove  the  front  wheels.  Refer  to 

4.4.5.1

 

Wheel

Replacement

.

4.

Remove the brake hose and brake pipe connecting bolts,
pull out the spring, and remove the brake hose from the
bracket.

2

1

FE06-0040b

5.

Remove the brake hose bolts (1), disconnect the brake
hose from the shock absorber, remove the brake hose to
the brake cylinder connecting bolt (2).

6.

Remove the front brake hose.

Installation Procedure:

Warning!

Refer  to  "Brake  Pipe  Replacement  Warning"  in
"Warnings and Notices".

6-40

Hydraulic Brake

Brake System