Clutch Master Cylinder: Service and Repair

Master Cylinder

REMOVAL

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

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





4) Remove the air intake chamber.
5) Remove the clutch pipe from the master cylinder.
6) Remove the master cylinder and reservoir tank as a unit.





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) Install the instrument panel lower cover.
4) After bleeding air from the clutch system, ensure that the clutch operates properly.
5) Install the air intake chamber.

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 popping 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, bleeder screw, seat or hose, replace the faulty part.