Anti-Lock Brakes

DISASSEMBLY OF MASTER CYLINDER



Remove the set screw and pull out the reservoir.
Remove the cap and strainer from the reservoir.
Remove two grommets
Place cylinder in vise



- Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt, straight pin and gasket.

NOTE: Tape the screwdriver tip before use.




- Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.
- Remove the No.1 piston and spring by hand, pull straight out, not at an angle.

CAUTION: If pulled out at an angle, there possibility of damaging the cylinder bore.




- Place a rag on two wooden blocks and lightly tap the cylinder flange between the blocks until the piston drops out of cylinder.

INSPECTION OF MASTER CYLINDER COMPONENTS

NOTE: Clean the disassembled parts with compressed air.

- Inspect cylinder bore for rust or scoring
- Inspect cylinder for wear or damage If necessary, clean or replace the cylinder.

ASSEMBLY OF MASTER CYLINDER




Apply lithium soap base glycol grease to rubber parts indicated by arrows



Install two springs and pistons

CAUTION: Be careful not to damage the rubber lips on the pistons.

- Insert the spring.
- Align the grooves on the No.2 piston and master cylinder flange as shown, and insert the No.2 piston straight in, not at an angle.

CAUTION: If inserted at an angle, there is possibility of damaging the cylinder bore.

- Using a screwdriver, align the grooves again.

NOTE: Tape the screwdriver tip before use.

CAUTION: Be careful not to scratch the cylinder bore.

- Temporarily insert the straight pin, and check that it can be inserted easily.
- Insert the spring and No. 1 piston straight in, not at an angle.






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



Install piston stopper bolt
- Using a screwdriver, push the piston in all the way and insert the straight pin and then install the piston stopper bolt over the gasket. Torque the bolt.

Torque: 10 Nm (7 ft lb)





Install two grommets




Install reservoir

- Install the cap and strainer to the reservoir.
- Push the reservoir onto the cylinder.
- Install the set screw while pushing on the reservoir.

Torque: 1.7 Nm (15.2 in lb)





CAUTION: Because the master cylinder and reservoir tank union is a grommet type, the set screw is designed to not separate the reservoir from the cylinder and will not tighten down the reservoir. Therefore, there is a clearance at point A. Do not insert washers or an equivalent when tightening.