U.Hi.lS.iHiD.iHSin.nFPICUHi-DiSK
Brakes, wheels and tyres 7*9
5.4a Brake switch wiring connector
(arrowed) - TDM models
5.4b Brake switch wiring connectors
(arrowed) - TRX models
5.6a Brake hose banjo bolt (arrowed) -
TDM models
5.6b Brake hose banjo bolt (arrowed) -
TRX models
5.7a Reservoir mounting bolt
...
5.7b ... and hose clamp - TRX models
4
On TDM and TRX models, disconnect the
brake light switch wiring connector(s)
(see
illustrations).
On XTZ models, remove the
switch from the brake lever bracket.
5 Remove the front brake lever (see Chapter 6).
On TDM and XTZ models, remove the rear view
mirror.
6 Unscrew the brake hose banjo bolt and
separate the hose(s) from the master cylinder,
noting the alignment
(see illustrations).
Discard
the sealing washers as they must be renewed.
Wrap the end(s) of the hose(s) in a clean rag and
suspend in an upright position or bend down
carefully and place the open end(s) in a clean
container. The objective is to prevent excessive
loss of
brake fluid, fluid spills and system contamination.
7 On TRX models, unscrew the bolt securing
the reservoir to the bracket, then release the
clamp securing the reservoir hose to the union
on the master cylinder
(see illustrations).
Remove the reservoir cap and lift off the
diaphragm plate and the rubber diaphragm.
Drain the brake fluid from the reservoir into a
suitable container, then detach the reservoir
hose from its union on the master cylinder. Wipe
any remaining fluid out of the reservoir with a
clean rag.
8 Unscrew the master cylinder clamp bolts, then
lift the master cylinder away from the handlebar
(see illustrations).
9
On TDM and XTZ models, remove the
reservoir cover retaining screws and lift off the
cover, the diaphragm plate and the rubber
diaphragm. Drain the brake fluid from the
reservoir into a suitable container. Wipe any
remaining fluid out of the reservoir with a
clean rag.
10 If required, on TDM and TRX models,
remove the brake light switch (see Chapter 9).
Overhaul
11 On TDM models, thread the adjuster off the
pushrod and remove the spring (where fitted),
the nut and the plate.
12 Carefully remove the dust boot from the
master cylinder
(see illustration).
5.8a Master cylinder clamp bolts
(arrowed) - TRX models
5.8b Master cylinder clamp bolts
(arrowed) - XTZ models
5.12 Remove the rubber boot from the end of
the master cylinder piston ...
Scaned by Stalker
