Disassembly and Assembly

DISASSEMBLY
1. REMOVE RESERVOIR
Remove the set screw and pull out the reservoir.
Torque: 1.8 Nm (18 kgf-cm, 16 inch lbs.)
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE





4. 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.

5. REMOVE 2 PISTONS AND SPRINGS





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





b. 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.





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

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.