Overhaul

DISASSEMBLY/ASSEMBLY

CAUTION:
- The brake master cylinder is made of aluminum, and can be easily damaged by tightening In a vise. When securing the master cylinder in a vise, tighten only the front ports of the cylinder body.

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of removal.

NOTE:
- If the master cylinder body is damaged, replace the unit as an assembly.

Piston Component Disassembly Note

- Loosen the cap by using the SST, and remove the primary piston component from the cylinder.

Piston Component Assembly Note

1. Before assembly, clean the cylinder body inner surface and a new piston component by using brake fluid.

2. Install the secondary spring component into the cylinder body with the retainer facing the cylinder body.

3. Apply the specified grease (supplied in the repair kit) to the cup of the secondary piston component.

4. Install the secondary piston component into the cylinder body with the hole in the piston component facing the cylinder body.

5. Using the old sleeve of the primary piston component, push the secondary piston component into the cylinder body.

CAUTION:
- Holding only the piston or the sleeve of the primary piston component could allow the components to fall out and become damaged. When handling the primary piston component, hold the cap and keep the component level.

6. Apply the specified grease (supplied in the repair kit) to the cup of the primary piston component.

7. Install the primary piston component into the cylinder body while keeping the piston component and the cylinder body horizontal.

8. Tighten the cap by using the SST.

Tighten Torque
12 - 15 Nm (1.2 - 1.6 kgfm, 8.7 - 11 ft. lbs.)

9. Measure clearance between the cylinder body flange and the cap.

Clearance
14.3 mm (0.562 inch) max.

10. If the clearance is greater than specified, disassemble and reassemble in the master cylinder.

Tank Retainer Assembly Note

- Install the tank retainer while pushing the reserve tank to the cylinder body.