Disassembly and Assembly

DISASSEMBLY
1. REMOVE RESERVOIR
a) Remove the set screw and pull out the reservoir.
Torque: 11.7 Nm (18 kgf-cm) 16 inch lbs.
b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. ABS only:
PLACE CYLINDER IN VISE





4. ABS only:
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket.

HINT: Tape the screwdriver tip before use.

Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
5. ABS only:
REMOVE 2 PISTONS AND SPRINGS





a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.

HINT: Tape the screwdriver tip before use.

b) Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle.

NOTICE:
^ If pulled out and instilled 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 No. 2 piston 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 inch).

6. w/ TRAC, w/ VSC:
REMOVE 2 PISTONS AND SPRINGS





a) Push in the piston with a screwdriver, and remove the 2 straight pins by turning over the cylinder body.

HINT: Tape the screwdriver tip before use.





b) Remove the 2 pistons and springs by hand, pulling straight out, not at angle.

NOTICE:
^ If pulled out and installed 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.

HINT: At the time of reassembly, insert the pistons with elliptic hole facing vertically.

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.