- Remove mud and dirt from the surface of the brake master cylinder.
- Prepare the tools necessary for disassembly operation, and arrange them neatly on work bench.
- Clean the work bench.
- Remove the pin with drift pin which secures the reserve tank to master cylinder.
- Remove the cylinder pin with magnetic pick-up tool while pushing in primary piston. See Fig 1
.
- Pry up the pawl and remove the piston retainer (models not equipped with VDC). See Fig 2
.
NOTE:
Piston may jump out from master cylinder.
- Using pliers, remove "C" ring (models equipped with VDC). See Fig 3
.
NOTE:
Piston may jump out from master cylinder.
- Extract the primary piston assembly and secondary piston assembly.
CAUTION:
Do not disassemble the piston assembly; otherwise, the spring set value may be changed. Use brake fluid or methanol to wash inside wall of cylinder, piston and piston cups. Be careful not to damage parts when washing. If methanol is used for washing, do not dip rubber parts, such as piston cups, in it for more than 30 seconds; otherwise, they may become swelled.
- If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston assembly, secondary piston assembly, supply valve stopper, or gasket, replace the faulty part.
CAUTION:
The primary and secondary pistons must be replaced as complete assemblies. The service limit of the clearance between each piston and the master cylinder inner diameter is 0.0043" (0.11 mm). When handling parts, be extremely careful not to damage or scratch the parts, or let any foreign matter get on them.