Disassembly and Assembly

DISASSEMBLY
1. REMOVE RESERVOIR
a) Remove the cap and strainer.
b) Remove the set screw and pull out the reservoir.
Torque: 1.8 Nm (18 kgf-cm, 16 inch lbs.)
2. REMOVE 2 GROMMETS





3. REMOVE STRAIGHT PIN
Push in the piston by hand and remove the straight pin by turning over the cylinder body.





HINT: At the time of reassembly, please refer to the following item. Insert the piston with elliptic hole facing horizontally.

4. PLACE MASTER CYLINDER IN VISE
5. REMOVE NO. 1 AND NO. 2 PISTONS





a) Push in the No. 1 piston by hand, 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 they are 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.





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 and spring drop 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. REMOVE WRING 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
Reassembly is to be done in the reverse order of disassembly.

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