Disassembly and Assembly

DISASSEMBLY





1. REMOVE RESERVOIR
(a) Using pliers, slide the 2 clips and remove the reservoir hoses and clips from the reservoir.

HINT: At the time of reassembly, install the reservoir hose with a paint line facing upward.

(b) Remove the cap, strainer from the reservoir.

2. PLACE MASTER CYLINDER IN VISE





3. REMOVE INLET UNION
(a) Using a pin punch (5 mm) and hammer, remove the pin from the cylinder body.
(b) Pull out the inlet union.
4. REMOVE 2 GROMMETS





5. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the No.1 piston by hand, remove the snap ring with snap ring pliers.





(b) Push in the piston with a screwdriver, and remove the straight pin by turning over the cylinder body.

HINT: Tape the screwdriver tip before use.

(c) Remove the No.1 position and spring by hand, pulling straight out, not at an angle.

NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.





(d) Place a rag and 2 wooden block on the work table, and lightly tap the cylinder flange against the block edges until the No.2 piston and spring drops out of the cylinder.

HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.).

6. REMOVE 0-RING FROM CYLINDER BODY


INSPECTION

HINT: Clean the disassembled parts with compressed air.

1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

REASSEMBLY

NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows shown in exploded view.

1. PLACE CYLINDER IN VISE





2. INSTALL SPRING AND NO.2 PISTON
(a) Install the spring and No.2 piston into the cylinder body.
(b) Push in the piston with a screwdriver, and install the straight pin to the cylinder body.

HINT:
- Tape the screwdriver tip before use.
- Insert the piston with elliptic hole facing horizontally.

NOTICE: Be careful not to damage the rubber lips on the pistons.





3. INSTALL NO.1 PISTON AND SPRING
(a) Install the No.1 piston and spring into the cylinder body.
(b) Push in the piston by hand, install the snap ring with snap ring pliers.
4. INSTALL 2 GROMMETS





5. INSTALL INLET UNION
(a) Install the inlet union to the cylinder body.
(b) Using a pin punch (5 mm) and hammer, drive in the pin.
6. INSTALL 0-RING TO CYLINDER BODY