Overhaul

BRAKE MASTER CYLINDER

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

DISASSEMBLY





1. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Fix the brake master cylinder in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

(b) Using a pin punch and hammer, tap out the straight pin.
(c) Remove the master cylinder reservoir and 2 grommets.
(d) Remove the filler cap and strainer from the master cylinder reservoir.





2. REMOVE BRAKE MASTER CYLINDER KIT
(a) Push in the piston and remove the snap ring using snap ring pliers.





(b) Push in the piston and remove the piston stopper bolt and gasket.
(c) Remove No. 1 piston from the master cylinder body by pulling it straight out.

NOTICE: Do not scratch the inside of the cylinder body.





(d) Tap the flanged part against wooden blocks until the end of No. 2 piston comes out. When the end of No. 2 piston comes out, pull No. 2 piston straight out of the master cylinder body.

NOTICE: Do not scratch the inside of the cylinder body.

REASSEMBLY
1. INSTALL BRAKE MASTER CYLINDER KIT
(a) Fix the master cylinder body in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.





(b) Apply lithium soap base glycol grease to the rubber part as shown in the illustration.
(c) Install No. 1 piston and No. 2 piston onto the master cylinder body.

NOTICE:
^ Install the piston straight while being not to careful damage the inside of the cylinder.
^ Do not damage the lip of the cylinder cup.





(d) Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)





(e) Install the snap ring using snap ring pliers with the piston pushed in.

NOTICE: Do not scratch the inside of the cylinder body.

2. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Install the strainer and filler cap onto the master cylinder reservoir.
(b) Apply lithium soap base glycol grease to the 2 grommets and install them onto the master cylinder body.
(c) Install the master cylinder reservoir onto the master cylinder body.





(d) Using a pin punch and hammer, tap in the straight pin.