Clutch Master Cylinder: Service and Repair

Master Cylinder

REMOVAL

1) Thoroughly drain the clutch fluid from the reservoir tank.
2) Remove the snap pin and clevis pin, and then separate the push rod of the master cylinder from clutch pedal.





3) Remove the air intake boot assembly.
4) Remove the clutch pipe from the master cylinder.
5) Remove the master cylinder and reservoir tank as a unit.

CAUTION:
Be careful not to spill the clutch fluid. Clutch fluid spilled on the vehicle body will harm the paint surface; wash it off with water and wipe clean quickly if spilled.





INSTALLATION

1) Install the master cylinder to the vehicle body, and connect the clutch pipe to the master cylinder.

Tightening torque:
T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb)





2) Connect the push rod of the master cylinder to the clutch pedal, and install the clevis pin and snap pin.

CAUTION:
Always use a new clevis pin.

NOTE:
Apply grease to the clevis pin.





3) After bleeding air from the clutch system, ensure that the clutch operates properly.
4) Install the air intake boot assembly.

DISASSEMBLY

1) Remove the straight pin and reservoir tank.





2) Remove the oil seal.





3) Move the seat towards the rear.





4) Remove the piston stop ring.

CAUTION:
When removing the piston stop ring, be careful to prevent the rod, washer, piston and return spring from coming out.

ASSEMBLY

1) Apply a coat of grease to the contact surfaces of the push rod and piston before installation.

Grease:
SILICONE GREASE G-40M (Part No. 004404003) or equivalent





2) Assemble in the reverse order of disassembly.

Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)

INSPECTION

If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, reservoir tank, return spring, breather screw, seat or clutch hose, replace the faulty part.