Disassembly and Assembly

CLUTCH MASTER CYLINDER
DISASSEMBLY
1. Remove the reservoir band, reservoir tank and reservoir cap.
2. Remove the piston stop ring and stopper.
3. Pull out the push rod and piston assembly.

NOTE: Do not damage the master cylinder body and piston assembly.

INSPECTION
1. Check the inside of cylinder body for rust pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for clogged.





5. Measure the master cylinder inside diameter with a cylinder gauge and the piston outside diameter with a micrometer.

NOTE: Measure the inside diameter of the master cylinder at three places (bottom, middle, and top), in perpendicular directions

6. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.
Limit: 0.15 mm (0.006 inch)

REASSEMBLY
1. Apply the specified fluid to the inner surface of the master cylinder body and to the entire periphery of the piston assembly
Specified fluid: BRAKE FLUID DOT 3





2. Install the piston assembly to master cylinder body in consideration of direction. (LHD only)
3. Install the stopper and piston stop ring.
4. Install the push rod assembly.
5. Install the reservoir band, reservoir hose, reservoir tank, and reservoir cap.