Disassembly and Assembly

Exploded View:

CAUTION:
- Avoid spilling fluid on painted, plastic or rubber parts as it may damage the finish.
- Plug the end of the brake hose with a shop rag to prevent brake fluid from flowing out of the brake hose after disconnecting.
- Use only new clean brake fluid.
- Clean all parts thoroughly with brake fluid. Blow out all passages with compressed air.
- Do not allow foreign matter to enter the system.
- Be careful not to bend or damage the brake pipe when removing the master cylinder.

DISASSEMBLY

Removing Rod Seal:

1. Remove the rod seal.

Snap Ring Removal:

2. Push the secondary piston assembly, then remove the snap ring.

CAUTION: Avoid damaging the master cylinder wall.

3. Remove the stop bolt while pushing in the secondary piston assembly.

Piston Guide Removal:

4. Remove the piston guide, secondary piston assembly and primary piston assembly.

NOTE: If the primary piston assembly is difficult to remove, apply compressed air from the primary piston side outlet.

CAUTION:
- Do not use high pressure air or bring the nozzle too close to the inlet.
- Place a shop rag over the master cylinder to prevent the primary piston from becoming a projectile.

Secondary Spring Screw Removal:

5. Remove the screw from the secondary piston assembly, then remove the secondary spring.
6 Clean all parts with brake fluid.

ASSEMBLY

Primary Piston Cup Assembly:

1. Lubricate new piston assemblies with brake fluid, then fit them together.

Piston Guide Assembly:

Secondary Piston Assembly:

2. Install the piston assemblies in the master cylinder.

NOTE: To ease assembly, rotate the pistons while inserting.

Stop Bolt Installation:

3. Install the stop bolt and new sealing washer while pushing in the secondary piston assembly, then tighten the stop bolt.

Snap Ring Installation:

4. Install the snap ring while pushing in the secondary piston assembly.

Removing Rod Seal:

5. Install a new rod seal.

CAUTION: When connecting the brake pipes, make sure that there is no interference between the brake pipes and other parts.

NOTE: Master cylinder pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing master cylinder.