Rebuild

DISASSEMBLY

1. Clean the outside of the brake master cylinder thoroughly. Remove brake master cylinder filler cap. Drain all brake fluid from brake master cylinder.

NOTICE: Always discard used brake fluid.

Snap Ring:

2. Depress primary piston and remove snap ring from retaining groove at the open end of the bore.

NOTICE: If brake master cylinder is to be put into vise to aid in disassembly, mount into vise by flange only to avoid damage to bore or reservoir areas.

3. Remove primary and secondary piston assemblies from brake master cylinder. Tap open end of brake master cylinder on bench to remove pistons. If secondary piston does not readily come out, apply air pressure to secondary outlet port to assist removal.

ASSEMBLY

1. Dip replacement piston assemblies in clean DOT 3 brake fluid for lubrication prior to assembly into cylinder.
2. Install secondary (smaller) piston assembly into bore, spring end first.
3. Install primary piston assembly, spring end first.
4. Depress primary piston and install snap ring.
5. Fill brake master cylinder reservoir with DOT-3 brake fluid to MAX line to 4.0 mm (0.16 in) below.