Disassembly and Assembly

Disassembly





1. Loosen push rod lock nut A to remove clevis and lock nut A.
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from cylinder body. During removal, keep push rod depressed, to prevent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
5. Remove spring.
6. Remove pin using pin punch then remove nipple and seal.

Inspection
Inspect for the following, and replace parts if necessary.
- Damage, wear, rust, and pinholes on the cylinder inner wall
- Damage and deformation of the reservoir tank
- Weak spring
- Crack or deformation of the dust cover

Assembly
1. Install spring.
2. Apply rubber lubricant to the sliding part of piston assembly, and insert piston assembly into cylinder body.
3. After installing stopper to push rod, install stopper ring while keeping piston assembly depressed by hand, so that piston assembly will not pop out.

CAUTION: Stopper ring cannot be reused. Always use a new stopper ring for assembly.

4. Install dust cover.
5. Install clevis to push rod, and tighten lock nut A to the specified torque.
7.8 - 11.8 Nm (0.8 - 1.2 kg-m, 69 - 104 inch lbs.)
6. Install seal and nipple to cylinder body, and install pin using a pin punch.