Master Cylinder Replacement

REMOVAL PROCEDURE

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Remove the air box.
2. Perform the gear tension release procedure. Refer to Antilock Brake System (ABS) and Enhanced Traction System (ETS).





3. Disconnect the electrical connector from the fluid level switch.





4. Disconnect the electrical connectors from both of the ABS solenoids (1,2).





5. Remove the motor pack electrical connector (1).





6. Disconnect the brake pipe (1) tube nuts from the master cylinder and the modulator assembly (2).
7. Plug the open brake pipes (1) in order to prevent brake fluid loss and contamination.
8. Remove the master cylinder mounting nuts.





9. Remove the master cylinder (3) and the modulator assembly from the booster (2).

INSTALLATION PROCEDURE

Notice: Refer to Fastener Notice Fastener Notice in Service Precautions.





1. Install the master cylinder (3) and the modulator assembly to the booster assembly (2).
^ Tighten the master cylinder and the modulator assembly mounting nuts to 27 Nm (20 ft. lbs.).





2. Install the brake pipe tube nuts (1) to the master cylinder (2) and the modulator assembly.
^ Tighten the brake pipe tube nuts to 23 Nm (17 ft. lbs.).





3. Connect the electrical connector to the fluid level switch (1).





4. Connect the electrical connectors to both solenoids (1, 2).





5. Connect the motor pack electrical connectors (1).





6. Fill the master cylinder to the proper level with clean brake fluid.
7. Bleed the hydraulic system.