Repair Procedures

Removal

1. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.

NOTE:
In advance remove the ECU and battery.
Put aside the fuel pump by disconnecting the connectors and remove the mounting nuts.




2. Disconnect the clutch tube (B) from the master cylinder.
3. Remove the drive lower cover. (refer to BD group)
4. Remove the clutch pedal mounting nuts.




5. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).






Disassembly

1. Remove the piston stop ring.
2. Pull out the push rod and piston assembly.
3. Remove the reserve tank band, reserve tank cap, and reserve tank.

NOTE:
Use care not to damage the master cylinder body and piston assembly.
Do not disassemble the piston assembly.

Inspection

1. Check the inside of the 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 to make sure the clutch line tube is not clogged or restricted in any way.
5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.

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

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 in)

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 or DOT 4

2. Install the piston assembly.
3. Install the piston snap ring.
4. Install the push rod assembly.

Installation

1. Apply the specified grease to the snap pin and washer.

Wheel bearing grease :SAE J310, NLGI No.2

2. Install the clutch pedal mounting nuts.

Tightening torque
: 17 - 26Nm (1.7 - 2.6kgf.m, 12.3 - 18.8Ib-ft)




3. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B).




4. Install the driver lower cover. (refer to BD group)
5. Connect the flexible hose (A) of the brake reserve tank to the master cylinder.

NOTE:
Install the fuel pump, ECU and the battery in order.




6. Connect the clutch tube (B) to the master cylinder.
7. Bleed the air in the clutch system.(refer to Bleeding in Service Adjustment Procedure)