Service manual

BRAKE
Disassembly
I
Drain brake
fluid
2
Remove
stopper
bolt
3
Remove rubber boot
snap ring
and
stopper
ring
and
remove
push
rod
4
Take out
piston and other related
parts
from
cylinder
5
Remove
valve
cap
and
then remove
gasket
check
valve and check valve
spring
Note
Disassemble master
cylinder
carefully
so
that the
sliding
surfaces of
piston
and
piston
cup
are
not
damaged
Do not
remove fluid reservoir
unle
absolutely
necessary
Moreover do not
remove
piston cup
unless
piston
is
replaced
Inspection
I
Thoroughly
wash all
disassembled
parts
in
brake fluid
or alcohoL
Note Do not wash
rubber
parts
with mineral
oil
since
they
are deteriorated
When alcohol
is used however do not
immerse
rubber
parts
in
alcohol
longer
than 30 seconds
After
parts
are
cleaned dry
them with
compressed
air
2
Check
cylinder
and
piston
for
damage
and uneven
wear on the
sliding surface and for other defective
conditions
Replace
as
required
3
Replace
if the
cylinder
and
piston
clearance
is
more
than 0 15 mm
0
0059 in
Master
cylinder
inner diameter 19 05
mm
in
4
Replace piston
cup
packing
and valves if
damaged
worn weakened or
expanded
In
principle replace
piston
cup
gasket
and
valves
with
new
ones
whenever master
cylinder
is
disasSembled
5
Check
piston
return
springs
for
damage
wear and
other defective
conditions and
replace
as
necessary
6
Replace
others
if
deformed
dam
aged
oLdefective
Reassembly
I
Assemble
disassembly
master
cylinder
in
reverse
sequence
to
2
Apply
rubber
grease
to
piston cup
and other
rubber
parts
slightly Apply
brake
fluid
to other
component
partS
j
and
carry
out
the
operations carefully
o that
component
parts
are not
damaged
or no dust and oiher
foreign
materials
enter
cylinder
and
brake fluid
reseivoir
3
Tightening
torque
Valve
cap
6
to 9
kg
m
43 4
to 65 1 ft Ib
J
0
Reinstallation
Reinstall
master
cylinder
in
removal
reverse
sequence
to
2 Fill
reservoir with
brake fluid Bleed master
cylinder
and wheel
cylinder which
is
located nearest master
cylinder
Make sure that
no brake fluid leaks
Note Do not
use brake fluid other than
specified
3 For
pedal
height adjustment
refer to the
paragraph
covering pedal
adjustment
BR 3
4
Tightening
torque
Master
cylinder
2 1
to 25
kg
m
15
2
to 18
1
ft b