Brake Master Cylinder: Service and Repair

BRAKE MASTER W/PLATE CYLINDER SUB-ASSEMBLY
REPLACEMENT

1. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces.

2. REMOVE V-BANK COVER SUB-ASSEMBLY
3. REMOVE AIR CLEANER ASSEMBLY
4. REMOVE AIR CLEANER HOSE NO.1
5. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSEMBLY





a. Slide the clip and disconnect the reservoir tube.





b. Using SST(s), disconnect the 2 brake tubes from the brake master w/plate cylinder sub-assembly.
SST 09023-00101





c. Remove the 2 nuts, then check valve bracket and the brake master w/plate cylinder assembly.
6. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE: Make an adjustment with the brake booster assembly having no vacuum. (Depress the brake pedal several times with the engine stopped.)

HINT: Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assembly is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assembly is reinstalled and the brake booster assembly is replaced with a new one.

a. Apply the chalk to the tip of an accessory tool.

HINT: An accessory tool is enclosed with new brake master cylinder sub-assembly.





b. Place the accessory tool to the brake booster assembly.
c. Measure the clearance between the brake booster push rod and accessory tool.
Clearance: 0 mm (0 inch)

HINT: Adjust the clearance in following cases:
^ If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small.
^ If the chalk does not stick on the tip of the brake booster push rod, the clearance is large.





d. If clearance is outside of the specified range, fix the push rod using SST(s) and adjust the length of the protruding adjusting bolt.

SST 09737-00020

HINT: When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.

7. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSEMBLY





a. Install the brake master w/plate cylinder sub-assembly and the check valve bracket with the 2 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft. lbs.)





b. Using SST(s), connect the 2 brake tubes to the brake master w/plate cylinder assembly.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





c. Slide the clip and connect the reservoir tube.
8. INSTALL AIR CLEANER HOSE NO.1
9. INSTALL AIR CLEANER ASSEMBLY
10. INSTALL V-BANK COVER SUB-ASSEMBLY
11. FILL RESERVOIR WITH BRAKE FLUID
12. BLEED MASTER CYLINDER
SST 09023-00101
13. BLEED BRAKE LINE
14. CHECK FLUID LEVEL IN RESERVOIR
15. CHECK BRAKE FLUID LEAKAGE