Overhaul

Part 1 Of 2:

Part 2 Of 2:

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 Special Service Tool (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
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.

MASTER CYLINDER INSPECTION





1. Set the Special Service Tool (SST) as shown in the figure, and tighten the nut to the specified torque.

Tightening torque: 9.81-15.6 Nm (100-160 kgf-cm, 86.8-138 inch lbs.)

2. Turn the adjusting bolt until gap A is 21 mm (0.83 inch).





3. Install a radiator cap tester and the SST to the front port on the master cylinder. Apply air into the master cylinder and verify that the air pressure does not build up.
4. Tighten the adjustment bolt on the SST until gap A becomes 11 mm (0.43 inch). Raise the air pressure to 49 kPa (0.5 kgf/cm2, 7.1 psi) and verify that the pressure is held for more than 5 seconds.
5. Check the rear port on the master cylinder by using the same procedure.