Master Cylinder Disassembly/Assembly

Figure 5A-1 Exploded View Of Master Cylinder Assembly:

Figure 5A-4 Removing/Installing Set Screw:

Disassembly
1. Remove the cap and strainer from the reservoir.
2. Remove the set screw and pull out the reservoir.

Figure 5A-5 Removing/Installing Stopper Bolt:

3. Mount cylinder in a vise.
4. Remove the two grommets from the master cylinder.

CAUTION: Do not damage piston or cylinder wall.

5. Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket.

Figure 5A-6 Removing/Installing Snap Ring:

6. Push in the piston and remove the snap ring with snap ring pliers.

Figure 5A-7 Removing Piston From Cylinder:

7. Place a rag on two wooden blocks and lightly tap the cylinder flange between the blocks until the piston tip protrudes.
8. Remove the piston by hand, pulling straight out, not at an angle.

CAUTION: If pulled out at an angle, there is a possibility of damaging the cylinder bore.

Inspection:
1. Inspect the following parts for wear, cuts, corrosion, or other abnormal conditions:
- Cylinder body
- Reservoir
- Primary piston - cups and spring
- Secondary piston - cups and spring
- Grommets
2. Check the inlet port and return port for obstructions. Blow away any foreign matter with compressed air.

Figure 5A-8 Apply Brake Fluid At Assembly:

Assembly
1. Apply clean brake fluid to the rubber parts indicated by arrows.
2. Insert the two springs and pistons straight in, not at an angle.

CAUTION: Be careful not to damage the rubber lips on the pistons.

3. Install the snap ring while pushing in the piston.
4. Using a screwdriver, push the pistons in all the way and install the piston stopper bolt and gasket.
5. Torque piston stopper bolt to 10 Nm (7 ft. lb.)
6. Install two grommets.
7. Install the cap and strainer to the reservoir.
8. Push the reservoir onto the cylinder.
9. Install the set screw while pushing on the reservoir.
10. Torque the set screw to 1.7 Nm (15.2 in. lb.)

Figure 5A-9 Clearance "A":

CAUTION: Because the master cylinder and reservoir tank union is a grommet type, the set screw is designed not to separate the reservoir from the cylinder and will not tighten down the reservoir. Therefore, there is a clearance at point A. Do not insert washers or such when tightening.