Bleeding the hydraulic brake system

Bleed the hydraulic brake system whenever:

• the system is disassembled.
• a brake hose is loosened, disconnected or replaced.
• the brake fluid level is very low.
• brake operation is faulty.

NOTE:

• Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
• When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.

1. Bleed:

• Hydraulic brake system

a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).

c. Connect a clear plastic hose "1" tightly to the bleed screw "2".

A. Front

B. Rear

d. Place the other end of the hose into a container.

e. Slowly apply the brake several times.

f. Fully pull the brake lever or fully press down the brake pedal and hold it in position.

g. Loosen the bleed screw.

NOTE:

Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend.

h. Tighten the bleed screw and then release the brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

j. Tighten the bleed screw to specification.

k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-18.

WARNING After bleeding the hydraulic brake system, check the brake operation.