Overhaul

BRAKE MASTER CYLINDER

COMPONENTS (Part 1):

COMPONENTS (Part 2):

DISASSEMBLY
1. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Remove the stopper screw and reservoir sub-assembly.
(b) Remove the cap and strainer from the reservoir sub-assembly.
(c) Remove the 2 grommets from the master cylinder sub-assembly.
2. REMOVE BRAKE MASTER CYLINDER KIT
(a) Hold the master cylinder sub-assembly in a vise with the 2 aluminum plates in between.
(b) Remove the O-ring from the master cylinder sub-assembly.





(c) Push in the piston and remove the snap ring using snap ring pliers.

NOTICE: When pushing in the piston, the fluid left in the cylinder may spatter.





(d) without VSC: Push in the piston and remove the piston stopper bolt and gasket.





(e) with VSC: Push in the piston and remove the straight pin by turning over the cylinder body.

NOTICE: Use a shop rag to prevent damage.

(f) Remove the No. 1 piston from the master cylinder body by pulling it straight out.

NOTICE: Do not scratch the inside of the cylinder body.





(g) Tap the flanged part against wooden blocks until the end of the No. 2 piston comes out. When the end of the No. 2 piston comes out, pull out the No. 2 piston straight from the master cylinder body.

NOTICE: Do not scratch the inside of the cylinder body.

REASSEMBLY
1. INSTALL BRAKE MASTER CYLINDER KIT
(a) Placing aluminum plates between the vise and the master cylinder sub-assembly, place the master cylinder sub-assembly in the vise.
(b) Apply lithium soap base glycol grease to the rubber part as shown in the illustration.





(c) Install the No. 1 and No. 2 pistons to the master cylinder body.

NOTICE:
^ Install the piston straight carefully not to give any damage to the inside of the cylinder.
^ Do not damage the lip of the cylinder cup.
^ with VSC: Install the No. 2 piston with the pin hole facing upward.





(d) without VSC: Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)





(e) with VSC: Install the straight pin with the piston pushed in.

NOTICE: Make sure that the straight pin is installed correctly.





(f) Install the hole snap ring using snap ring pliers with the piston pushed in.

NOTICE: Do not scratch the inside of the cylinder body.

(g) Apply lithium soap base glycol grease to a new O-ring.
(h) Install the O-ring to the master cylinder body.
2. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Install the strainer and cap to the reservoir sub-assembly.
(b) Apply lithium soap base glycol grease to the 2 grommets and install them to the master cylinder body.
(c) Install the reservoir sub-assembly with the stopper screw.