3.18 Brake Lines
Fragment manuala — str. 118–123
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BRAKE LINES 3.18
FRONT CROSSOVER BRAKE LINE
Prepare
1. Drain front brake lines. See BLEED BRAKES (Page 3-49).
Remove
1. Detach brake line from front brake calipers. See FRONT
BRAKE CALIPER (Page 3-32).
2. See Figure 3-41. Remove brake line clamp fastener.
a. Lift fastener lock (1).
b. Remove fastener body (2).
3. Remove clamp from brake line.
a. Separate brake line clamp (3).
b. Remove brake line from grommet (4). 1. Fastener lock
2. Fastener body
3. Clamp
Install 4. Grommet
5. Front Caliper to ABS Module Brake Line
1. See Figure 3-41. Install clamp on brake line.
6. Crossover brake line
a. Install grommet on brake line (4). Figure 3-41. Brake Line Attachment, Front Fender
BRAKE LINE: FRONT MASTER CYLINDER
b. Install clamp on grommet (3). TO ABS MODULE
2. Install brake line clamp fastener. FASTENER TORQUE VALUE
Brake line, front, clamp screws 62-80 in-lbs 7-9 N·m
a. Install fastener body (2).
b. Press in fastener lock (1).
Prepare
1. Remove seat. See SEAT (Page 3-113).
3. Attach brake line to front brake calipers. See FRONT
BRAKE CALIPER (Page 3-32). 2. Remove fuel tank. See FUEL TANK (Page 6-13).
Complete 3. Remove frame crossmember. See FRAME
CROSSMEMBER (Page 3-123).
1. Fill and bleed front brake lines. See BLEED BRAKES
(Page 3-49).
4. Drain front brake lines. See BLEED BRAKES (Page 3-49).
Remove
1. Remove brake line from front brake master cylinder. See
FRONT BRAKE MASTER CYLINDER (Page 3-29).
2. Remove brake line from ABS module. See ABS MODULE
(Page 3-46).
3. See Figure 3-42. Remove screw (5) on fork top clamp.
4. Remove from wire form (1).
5. Remove clamp (3).
6. Remove grommet (4).
7. See Figure 3-43. Remove brake line left side clamps. Complete
a. Remove screws (2). 1. Fill and bleed brake system. See BLEED BRAKES
(Page 3-49).
b. Remove clamps (4,5).
2. Install frame crossmember. See FRAME CROSSMEMBER
c. Remove grommets (3). (Page 3-123).
8. Remove line clip (6). 3. Install fuel tank. See FUEL TANK (Page 6-13).
9. See Figure 3-44. Remove rear clamp. 4. Install seat. See SEAT (Page 3-113).
a. Remove screw (2).
b. Remove clamp (3).
c. Remove grommet (4).
Install
1. Place brake line in position.
2. NOTE
Do not tighten clamp screws until all screws have been
installed.
See Figure 3-44. Install rear clamp.
a. Install grommet (4).
b. Install clamp (3).
c. Install screw (2).
3. See Figure 3-43. Install line clip (6).
4. Install brake line left side clamps.
a. Install grommet (3). 1. Wireform
2. Brake line
b. Install clamps (4,5). 3. Clamp
4. Grommet
c. Install screw (2). 5. Screw
Figure 3-42. Brake Line Routing (forward)
5. See Figure 3-42. Install brake line in wire form (1).
6. Install clamp.
a. Install grommet (4).
b. Install clamp (3).
c. Install screw (5) on fork top clamp.
7. Install brake line at ABS module. See ABS MODULE
(Page 3-46).
8. Install brake line at front master cylinder. See FRON T
BRAKE MASTER CYLINDER (Page 3-29).
9. Tighten clamp screws.
Torque: 62-80 in-lbs (7-9 N·m) Brake line, front, clamp
screws
4. Drain front brake lines. See BLEED BRAKES (Page 3-49).
Remove
1. NOTE
Pan American has dual calipers with a crossover line
connecting them. Banjo fittings are stacked on right caliper.
Remove front caliper to ABS module brake line from front
brake caliper and fender. See Front Crossover Brake Line
in this section.
2. Remove brake line from ABS module. See ABS MODULE
(Page 3-46).
3. See Figure 3-45. Remove rear clamp.
1. Brake line
2. Screw (3) a. Remove screw (2).
3. Grommet (2)
4. Clamp (2) b. Remove clamp (3).
5. Clamp
6. Line clip c. Remove grommet (4).
Figure 3-43. Left Side Brake Line From Front Master Cylin
der 4. See Figure 3-46. Remove clips securing WSS and fork
solenoid, if equipped, to brake line.
5. Remove clamps (6,8).
a. Remove screws (5).
b. Remove clamps (6,8).
c. Remove grommets (7).
6. Remove brake lines line clip (3).
7. See Figure 3-45. Remove clamp (3). See Brake Line: Front
Master Cylinder to ABS Module in this section.
8. Remove brake line.
Install
1. Brake line 1. Place brake line in position.
2. Screw
3. Clamp 2. NOTE
4. Grommet Do not tighten clamp screws until all screws have been
Figure 3-44. Rear Brake Line Clamp installed.
BRAKE LINE: FRONT CALIPER TO ABS
See Figure 3-45. Install rear clamp.
MODULE
a. Install grommet (4).
FASTENER TORQUE VALUE
Brake line, front, clamp screws 62-80 in-lbs 7-9 N·m b. Install clamp (3).
Prepare c. Install screw (2).
1. Remove seat. See SEAT (Page 3-113).
3. See Figure 3-46. Install brake lines line clip (3).
2. Remove fuel tank. See FUEL TANK (Page 6-13).
4. Install brake line left side clamps.
3. Remove frame crossmember. See FRAME a. Install grommets (7).
CROSSMEMBER (Page 3-123).
b. Install clamps (6,8).
3-42 94000784
c. Install screws (5).
5. Install clips securing WSS and fork solenoid, if equipped,
to brake line.
6. Install brake line at ABS module. See ABS MODULE
(Page 3-46).
7. Install brake line at front caliper. See Front Crossover
Brake Line in this section.
8. Tighten clamp screws.
Torque: 62-80 in-lbs (7-9 N·m) Brake line, front, clamp
screws
Complete
1. Fill and bleed brake system. See BLEED BRAKES
(Page 3-49).
2. Install frame crossmember. See FRAME CROSSMEMBER 1. Line clip, WSS
(Page 3-123). 3. Line clip, brake lines
4. Brake line
3. Install fuel tank. See FUEL TANK (Page 6-13). 5. Screw (4)
6. Clamp (3)
4. Install seat. See SEAT (Page 3-113). 7. Grommet (3)
8. Clamp
Figure 3-46. Left Side Brake Line Routing
BRAKE LINE: REAR MASTER CYLINDER
TO ABS MODULE
FASTENER TORQUE VALUE
Brake line, rear dual, clamp 62-80 in-lbs 7-9 N·m
I
screw
Prepare
1. Remove seat. See SEAT (Page 3-113).
2. Drain rear brake lines. See BLEED BRAKES (Page 3-49).
3. Disconnect rear stoplamp switch. See REAR S TOPLAMP
SWITCH (Page 8-36).
1. Brake line Remove
2. Screw
3. Clamp 1. Remove brake line from rear brake master cylinder. See
4. Grommet REAR BRAKE MASTER CYLINDER (Page 3-34).
Figure 3-45. Rear Brake Line Clamp
2. Remove brake line from ABS module. See ABS MODULE
(Page 3-46).
3. See Figure 3-47. Remove brake line from clamp.
a. Remove screw (4).
b. Remove clamp (2).
c. Remove grommet (3).
4. Remove brake line.
94000784 3-43
Install
I
FASTENER TORQUE VALUE
Brake line, rear fork, clamp 62-80 in-lbs 7-9 N·m
1. See Figure 3-47. Install brake line.
screw
a. Install grommet (3).
Prepare
b. Install clamp (2). 1. Remove seat. See SEAT (Page 3-113).
c. Install screw (4). Tighten.
2. Remove upper chain guard. See CHAIN GUARDS
Torque: 62--80 in-lbs (7-9 N·m) Brake line, rear dual, (Page 3-76).
clamp screw
2. 3. Drain rear brake line. See BLEED BRAKES (Page 3-49).
Install brake line to ABS module. See ABS MODULE
(Page 3-46).
Remove
3. Install brake line to rear brake master cylinder. See REAR
1. See Figure 3-49. Remove line clip (4).
BRAKE MAS T ER CYLINDER (Page 3-34).
2. Remove brake line from rear fork.
Complete
1. Connect rear stoplamp switch. See REAR ST OPLAMP a. Remove screws (1).
SWITCH (Page 8-36).
b. Remove P-clamps (2) from brake line (5).
2. Fill and bleed brake system. See BLEED BRAKES
(Page 3-49). 3. See Figure 3-48. Remove brake line from clamp.
3. Install seat. See SEAT (Page 3-113). a. Remove clamp screw (2).
b. Remove clamp (4).
c. Remove grommet (3).
4. Remove brake line from rear caliper. See REAR BRAKE
CALIPER (Page 3-38).
5. Remove brake line from ABS module. See ABS MODULE
(Page 3-46).
6. Remove brake line.
Install
1. See Figure 3-48. Install brake line.
a. Install grommet (3).
b. Install clamp (4) and screw (2). Tighten.
Torque: 62--80 in-lbs (7-9 N·m) Brake line, rear dual,
clamp screw
2. See Figure 3-49. Install brake line on rear fork.
1. Brake Line a. Install brake line (5) with WSS wire (3) into P-clamps
2. Clamp (2).
3. Grommet
4. Screw b. Install screws (1). Tighten.
Figure 3-47. ABS Module to Rear Master Cylinder Brake Torque: 62--80 in-lbs (7-9 N·m) Brake line, rear fork,
Line clamp screw
BRAKE LINE: REAR CALIPER TO ABS
MODULE 3. Install line clip (4).
screw
FASTENER
Brake line, rear dual, clamp I
TORQUE VALUE
62-80 in-lbs 7-9 N·m
4. Install brake line to ABS module. See ABS MODULE
(Page 3-46).
5. Install brake line to rear brake caliper. See REAR BRAKE
CALIPER (Page 3-38).
Complete
1. Fill and bleed brake system. See BLEED BRAKES
(Page 3-49).
2. Install upper chain guard. See CHAIN GUARDS
(Page 3-76).
3. Install seat. See SEAT (Page 3-113).
1. Screw (2)
2. P-clamp (2)
3. WSS wire
4. Line clip
5. Brake line
Figure 3-49. Rear Brake Line and WSS Routing
1. Brake line
2. Screw
3. Grommet
4. Clamp
Figure 3-48. Brake Line at ABS Module
94000784 3-45