Disassembly and Assembly

DISASSEMBLY
1. REMOVE RESERVOIR
a. Remove the set screw and pull out the reservoir.
b. Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. Except w/ TRAC: PLACE CYLINDER IN VISE





4. Except w/ TRAC: REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket.

HINT: Tape the screwdriver tip before use.

5. Except w/ TRAC: REMOVE 2 PISTONS AND SPRINGS





a. Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.

HINT: Tape the screwdriver tip before use.

b. Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle.

NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.





c. Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No. 2 piston drops out of the cylinder.

HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 inch).





6. w/ TRAC: REMOVE 2 PISTONS AND SPRINGS
a. Push in the piston with a screwdriver, and remove the 2 straight pins by turning over the cylinder body.

HINT: Tape the screwdriver tip before use.

b. Remove the 2 pistons and springs by hand, pulling straight out, not at an angle.

NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.

INSPECTION

HINT: Clean the disassembled parts with compressed air.

1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

REASSEMBLY

NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows.

1. Except w/TRAC: PLACE CYLINDER IN VISE





2. Except w/ TRAC: INSTALL 2 PISTON AND SPRINGS
a. Install the 2 piston and springs into the cylinder body.
b. Push in the piston with a screwdriver and install the snap ring with snap ring pliers.

HINT: Tape the screwdriver tip before use.

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





3. Except w/ TRAC: INSTALL PISTON STOPPER BOLT
Using a screwdriver, push the piston in all the way and install the piston stopper bolt and gasket.

HINT: Tape the screwdriver tip before use.

Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)





4. w/ TRAC: INSTALL 2 PISTONS AND SPRING
a. Install the 2 piston and springs into the cylinder body.
b. Push in the piston with a screwdriver, and install the 2 straight pins to the cylinder body.

HINT:
^ Tape the screwdriver tip before use.
^ Insert the pistons with elliptic hole facing vertically.

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

5. INSTALL 2 GROMMETS
6. INSTALL RESERVOIR
a. Install the strainer and cap to the reservoir.
b. Install the reservoir and set screw.
Torque: 1.7 Nm (18 kgf-cm, 16 inch lbs.)