Master Cylinder Overhaul (Non-ABS)

DISASSEMBLY PROCEDURE

CAUTION: Wear safety glasses in order to avoid eye damage.

CAUTION:
^ Refer to Brake Fluid Irritant Caution in Service Precautions.
^ Refer to Brake Fluid Caution in Service Precautions.

NOTICE:
^ Refer to Filling the Master Cylinder Notice in Service Precautions.
^ Refer to Honing The Master Cylinder Bore Notice in Service Precautions.
^ Refer to Master Cylinder Body Notice in Service Precautions.





1. Remove the reservoir (2) from the master cylinder (4).
2. Remove the master cylinder from the booster.





3. Remove the piston stopper snap ring (1) from the master cylinder (2).
4. Remove the piston stopper.
5. Remove the cylinder cup.
6. Remove the plate.
7. Pull the primary piston assembly and the O-ring carefully from the master cylinder in order to prevent damage to the inside of the master cylinder wall.
8. Remove the secondary piston stopper bolt and the washer from the master cylinder.

CAUTION: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.

NOTICE: Do not use lubricated compressed air on brake parts as damage to rubber components may result.

9. Remove the secondary piston assembly by blowing compressed air into the secondary piston stopper bolt hole.
10. Remove the piston cup and the secondary piston pressure cup.
11. Remove the spring.
12. Inspect all disassembled parts for wear or damage. Replace parts if necessary.

IMPORTANT: DO NOT reuse piston cups.

13. Wash disassembled parts with brake fluid.
14. Inspect the master cylinder bore for scoring or corrosion (pits or excessive roughness). Replace a corroded master cylinder.

IMPORTANT: DO NOT use a cloth in order to dry the cylinder, because lint from a cloth will stick to the cylinder bore surfaces.

15. Rinse the cylinder in clean brake fluid. Shake excess rinsing fluid from the cylinder.

ASSEMBLY PROCEDURE





1. Install the spring to the master cylinder (2).
2. Install the following to the master cylinder:
^ The new piston cup
^ The secondary piston assembly
^ The new secondary piston pressure cup

3. Install the O-ring and the primary piston to the master cylinder.
4. Install the plate.
5. Install the new cylinder cup.
6. Install the piston stopper.





7. Depress and install the piston stopper snap ring into the master cylinder (2).

NOTICE: Refer to Fastener Notice in Service Precautions.

8. With the pistons pushed entirely inside the cylinder, install the piston stopper bolt.
^ Tighten the stopper bolt to 10 Nm (88.5 inch lbs.).

9. Install the master cylinder to the brake booster.





10. Apply a thin coat of brake fluid around the new grommets (3), and install the grommets to the master cylinder (4).
11. Install the reservoir.