Clutch Master Cylinder: Service and Repair
Master Cylinder and Reservoir TankA: REMOVAL
1. Thoroughly drain brake fluid from reservoir tank.
2. Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal.
3. Remove air cleaner case and air intake duct.
4. Remove clutch pipe from master cylinder.
5. Remove master cylinder with reservoir tank.
CAUTION: Be extremely careful not to spill brake fluid. Brake fluid spilt on the vehicle body will harm the paint surface; wipe it off quickly if spilt.
B: DISASSEMBLY
1. Remove straight pin and reservoir tank.
2. Remove oil seal.
3. Move the cylinder boot backward.
4. Remove snap ring.
CAUTION: Be careful when removing the snap ring to prevent the rod, washer, piston and return spring from flying out.
C: INSPECTION
If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring and gasket, replace the faulty part.
D: ASSEMBLY
1. Apply a coat of grease to the contacting surfaces of the push rod and piston before installation.
Grease: SILICONE GREASE G40M (Part No. 004404003)
2. To assemble the master cylinder reverse the sequence of disassembly procedure.
E: INSTALLATION
1. Install master cylinder to body, and install clutch pipe to master cylinder.
CAUTION: Check that pipe is routed properly.
Tightening torque:
T: 18 ± 3 Nm (1.8 ± 0.3 kg-m, 13.0 ± 2.2 ft. lbs.)
2. Connect push rod of master cylinder to clutch pedal, and install clevis pin and snap pin.
NOTE: Apply grease to clevis pin.
3. After bleeding air from system, ensure that clutch operates properly.
4. Install air cleaner case and air intake duct.