Reassembly

BRAKE: BRAKE MASTER CYLINDER: REASSEMBLY

BRAKE MASTER CYLINDER: REASSEMBLY

1. CHECK BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Check the inside of the master cylinder for scratch.
If necessary, replace the master cylinder.
2. INSTALL BRAKE MASTER CYLINDER KIT





(a) Place aluminum plates between the vise and master cylinder. Place the master cylinder in a 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 pistons straight carefully not to give any damage to the inside of the cylinder.
- Do not damage the lip of the cylinder cup.





(d) Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)





(e) Using snap ring pliers, install the hole snap ring with the piston pushed in.
NOTICE: Do not scratch the inside of the cylinder body.

(f) Apply lithium soap base glycol grease to a new O-ring.
(g) Install the O-ring to the master cylinder body.





3. INSTALL UNION
(a) Apply lithium soap base glycol grease and silicon grease to the 2 grommets as shown in the illustration.
(b) Install the 2 grommets to the master cylinder body.
(c) Install the master cylinder union with the stopper screw.
4. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD





(a) Set SST on the master cylinder and lower the rod of the SST until it slightly touches the piston.
SST: 09737-00013
HINT: SST: 09737-00012 can also be used.

(b) Apply chalk to the flat tip of the SST rod. Turn the SST upside down and measure the clearance between the brake booster push rod and the SST.
Clearance:
0 mm (0 in.)
If there is a clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far.
If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.





(c) If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.
SST: 09737-00020
HINT: Check the push rod clearance again after adjustment.