Disassembly and Assembly

DISASSEMBLY





1. REMOVE MASTER CYLINDER BOOT
Using a screwdriver, remove the master cylinder boot.

HINT: At the time of reassembly, please refer to the following item. With the UP mark on the master cylinder boot facing upwards, install the cylinder boot on the master cylinder.

2. REMOVE RESERVOIR
Remove the set screw and pull out the reservoir.
Torque: 1.7 Nm (17.5 kgf.cm, 15.2 ft. lbs.)
3. REMOVE 2 GROMMETS
4. PLACE CYLINDER IN VISE





5. w/ TRAC: REMOVE NO.1 PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove the No. 1 piston stopper bolt and gasket.

HINT: Tape the screwdriver tip before use.

Torque: 10 Nm (100 kgf.cm, 7 ft. lbs.)
6. REMOVE NO. 2 PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove the No. 2 piston stopper bolt and gasket.
Torque: 10 Nm (100 kgf.cm, 7 ft. lbs.)
7. REMOVE PISTONS





a. Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.
b. Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle.

NOTICE:
^ If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
^ At the time of reassembly, be careful not to damage the rubber lips on the pistons.





c. Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the block edges until the piston drops out of the cylinder.

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

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
Reassembly is in the reverse order of disassembly.





HINT: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows.