Brake Master Cylinder: Service and Repair

REMOVAL





1. Detach the brake tubes from the master cylinder, and then install the plugs.

CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.

2. Remove the master cylinder mounting nuts, and then lift out the master cylinder.

DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.





2. Remove reservoir from the master cylinder.

NOTE: When bleeding by pressurized fluid, do not press the brake pedal.





3. Using snap ring pliers, remove the retaining ring.
4. Remove the piston stopper (ABS only).
5. Remove the primary piston assembly.





6. Using a screwdriver, push the secondary piston all the way down and remove the piston stopper (ABS only). Remove the secondary piston assembly.

NOTE: Do not disassemble the primary and secondary piston assembly.

INSPECTION
1. Inspect the cylinder bore for rust or scoring.
2. Inspect the master cylinder for wear or damage. If necessary, clean or replace the cylinder.

NOTE:
1 If bore is damaged, replace the master cylinder assembly. Do not attempt to bone bore.
2 Clean the master cylinder body with isopropyl alcohol to remove any contamination.

ASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.





2. Carefully insert the two springs and pistons straight in.





3. Push the pistons in with a screwdriver and install the retaining ring.
4. Using a screwdriver, push the piston all the way and install the piston stopper.





5. Mount the two grommets.
6. Install the reservoir onto the cylinder.

INSTALLATION
1. Inspect the length of output rod and adjust (8.25 - 0.125 mm).
2. Install the master cylinder on the brake booster.





3. Connect the brake tubes to the master cylinder.
4. Fill brake reservoir with brake fluid and bleed the system.