4. Inspect the banjo-fitting and bolt for cracks and deterioration and the condition of the fittings Hand Brake Lever/ (threaded and compression). Master Cylinder INSTALLING Assembly 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. 2. Using two new crush washers, connect the banjo-fitting to the master cylinder; then secure with the banjo-fitting bolt. Tighten to 20 ft-lb. REMOVING 3. Bleed the brake system (see Section 2). 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a container. Remove the reservoir cover; then open the bleeder valve. Allow the brake fluid to drain Throttle Control completely. NOTE: Compressing the brake lever several times will quicken the draining process. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar. 2. Slide the grommet out of the lower half of the throttle control; then remove the cable from the actuator arm. AF637D 2. Place an absorbent towel around the connection to absorb brake fluid. Remove the banjo-fitting bolt from the master cylinder. Account for two crush washers and a banjo-fitting bolt. ! CAUTION AF676D Brake fluid is highly corrosive. Do not spill brake 3. Remove the cap screw, lock washer, and washer fluid on any surface of the ATV. securing the actuator arm to the throttle control lever. 3. Remove the clamp screws securing the brake housing to the handlebar, then remove the assem- bly from the handlebar. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the pin securing the brake lever for wear. 2. Inspect the brake lever for elongation of the pivot hole. AF677D 3. Inspect the reservoir for cracks and leakage. 4. Remove the actuator arm and account for a bush- ing. Note the position of the return spring for installing purposes. 9-2