REAR MASTER CYLINDER. Honda CBR125R

INSTALLATION

Install the master cylinder, holder ("UP" mark facing up) and bolts.

Align the end of the master cylinder with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt.

HOLDER

HYDRAULIC BRAKE

MASTER CYLINDER

BOLTS

Connect the brake light switch connectors.

Install the brake hose eyelet with the brake hose oil bolt and new sealing washers.

Push the brake hose eyelet joint against the stopper, then tighten the brake hose oil bolt to the specified torque.

TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)

Install the right rearview mirror.

Fill the reservoir to the upper level and bleed the

front brake system (page 15-6).

CONNECTORS

REAR MASTER CYLINDER

REMOVAL

Drain the brake fluid from the hydraulic system

(page 15-5).

When removing the oil bolt, cover the end of the brake hose to prevent contamination.

Remove the brake hose oil bolt, sealing washers and brake hose eyelet.

Loosen the master cylinder mounting bolts.

BOLTS

"UP" MARK Align

SEALING WASHERS

OIL BOLT

STOPPER

OIL BOLT

Remove the step holder mounting bolts and right step holder assembly.

SEALING WASHERS

BOLTS

STEP HOLDER ASSEMBLY

15-15

HYDRAULIC BRAKE

Remove the cotter pin, joint pin and master cylinder from the brake pedal.

BRAKE PEDAL

JOINT PIN

Remove the master cylinder mounting bolts and master cylinder from the right step holder assembly.

MASTER CYLINDER

MASTER

CYLINDER

COTTER PIN

DISASSEMBLY

Remove the hose joint screw, O-ring and reservoir hose joint.

STEP HOLDER ASSEMBLY BOLTS

SCREW

Be careful not to damage the boot.

Remove the boot.

Remove the snap ring using a special tool.

TOOL:

Snap ring pliers 07914-SA50001

HOSE JOINT/O-RING

SNAP RING

BOOT

15-16

Remove the push rod, master piston/spring and separate them.

Clean the inside of the master cylinder and master piston with brake fluid.

MASTER CYLINDER

HYDRAULIC BRAKE

PISTON

INSPECTION

Check the master cylinder for scoring, scratches or damage.

Check the master piston for scoring, scratches or damage.

Check the piston cups for wear, deterioration or damage.

SPRING

PUSH ROD

MASTER PISTON

MASTER CYLINDER PISTON CUPS

Measure the master cylinder I.D.

SERVICE LIMIT: 12.755 mm (0.5022 in)

Measure the master piston O.D.

SERVICE LIMIT: 12.645 mm (0.4978 in)

Check the following:

– Push rod for bent

– Boot for damage

– Rod joint for damage

Remove the pin and replace the damaged part if necessary.

PUSH ROD

BOOT

ROD JOINT

PIN

15-17

HYDRAULIC BRAKE

ASSEMBLY

1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

RESERVOIR COVER

SET PLATE

1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

HOSE JOINT

O-RING

MASTER CYLINDER

DIAPHRAGM

RESERVOIR

SPRING

MASTER PISTON

SNAP RING

PUSH ROD

BOOT

17 N·m (1.7 kgf·m, 13 lbf·ft)

PIN

BRAKE ROD JOINT

Do not allow the piston cup lips to turn inside out.

Replace the piston, spring and cups as a set.

Apply brake fluid to the master piston sliding area.

Install the spring onto the piston end.

Install the master piston/spring into the master cylinder.

Apply silicone grease to the push rod contacting

area (page 1-17).

Install the push rod into the master cylinder.

MASTER CYLINDER

SPRING

PISTON

PUSH ROD

SNAP RING

Make sure the snap ring is firmly seated in the groove.

Install the snap ring into the groove of the master cylinder using a special tool.

TOOL:

Snap ring pliers 07914-SA50001

15-18

Apply silicone grease to the boot groove of the push rod.

Install the boot securely.

HYDRAULIC BRAKE

BOOT

If the push rod joint is reinstalled, adjust the push rod length so that the distance from the center of the master cylinder lower mounting hole to the center of the joint pin hole is 84 – 86 mm (3.3 – 3.4 in) as shown.

After adjustment tighten the push rod lock nut to the specified torque.

TORQUE: 17 N·m (1.7 kgf·m, 12 lbf·ft)

LOCK NUT

Install a new O-ring to the reservoir hose joint and install them to the master cylinder.

Apply locking agent to the hose joint screw threads and install it

Tighten the hose joint screw to the specified torque.

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

O-RING

84 – 86 mm

(3.3 – 3.4 in)

SCREW

HOSE JOINT

INSTALLATION

Install the master cylinder and master cylinder mounting bolts to the right step holder assembly.

MASTER CYLINDER

STEP HOLDER ASSEMBLY BOLTS

15-19