Without ACC

MASTER CYLINDER:

Disassembly and Assembly
DISASSEMBLY



Models without ACC





1. Tighten the flange of the cylinder body in base in the figure.

CAUTION: Pay attention to the orientation of master cylinder body.
Use the copper plate or closes for fixing the body in the vise.







2. Using the pin-punch (commercial service tool: die approximately 4 mm), remove pin form the reservoir tank.
3. Remove the master cylinder assembly from the vise.
4. Remove the reservoir tank and grommet from the cylinder body.







5. Push the primary piston and remove the stopper pin from secondary tank boss hole in the cylinder body.

CAUTION: Be careful not to damage the inner wall of the cylinder.







6. Remove the snap ring in pushing primary piston.

CAUTION: Be careful not to put out the piston.

7. Holding the rod of the primary piston, remove the primary piston assembly, the plate and the guide with pulling straight to prevent the cup from being caught by the inner wall of the cylinder.
8. Remove the plate and the guide from the primary piston.

CAUTION: Be careful not to damage the rod from the inner wall of the plate.







9. Tap the flange using a soft block such as wood, and carefully pull the secondary piston assembly straight out to prevent the inner wall of the cylinder from being damaged.





INSPECTION AFTER DISASSEMBLY

Master Cylinder
Check the inner wall of the cylinder for damage, wear, corrosion, and pin holes. Replace the cylinder if a malfunction is detected.




ASSEMBLY

CAUTION: Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
Make sure that there is no foreign material such as dirt and dust on the inner wall of the cylinder, piston, and cup seal. Be careful not to damage the parts with a service tool when assembling.
Do not drop the parts. Do not use any dropped parts.




Models without ACC





1. Apply brake fluid to the inner wall of cylinder body and contact surface of the piston assembly.
2. Insert secondary piston and primary piston assembly into cylinder body in this order.

CAUTION: Do not reuse the primary and secondary piston assemblies.
Pay attention to the orientation of the piston cup, and insert straight to prevent the cup from being caught by the inner wall of the cylinder.
Always replace the inner kit as an assembly.







3. Align the slit in the center of the piston with the axial direction of the valve stopper to assemble. Visually check the secondary piston slit from the valve stopper mounting hole, and install the valve stopper.

CAUTION: Always replace the piston pin O-ring with new one in the repair kit.







4. Insert the plate and the guide into the cylinder body.

CAUTION: Be careful not to damage the rod of the primary piston.
Pay attention to the orientation of the guide.
Do not drop the O-ring.







5. Be careful not to damage the rod of the primary piston with covering the close. Then insert snap ring to cylinder with pushing primary piston.

CAUTION: Be careful to check the snap ring in the inner tip of the cylinder body.
Do not reuse the snap ring.







6. Tighten the flange of the cylinder body in the figure.


CAUTION: Using the copper plate or closes to cover the flange for fixing base.
Pay attention to the orientation of the cylinder body.

7. Apply brake fluid to a grommet, and press it into the master cylinder to install.

CAUTION: Do not reuse the grommet.







8. Install the reservoir tank to the master cylinder.

CAUTION: Pay attention to the orientation of the reservoir tank.







9. Set the reservoir tank in the front direction to the cylinder body.
Press a new reservoir tank in the cylinder body.

CAUTION: Pay attention to the orientation of the piston cup, and insert straight to prevent the cup from being caught by the inner wall of the cylinder.