Removal and Replacement

Master Cylinder Removal and Installation

Removal

CAUTION:
^ Never disassemble master cylinder since the master cylinder is supplied as assembly parts. If faulty condition is found, replace it with new one.
^ Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid flush it with water immediately if any fluid is spilled.

1. Clean outside of master cylinder.
2. Disconnect fluid level switch coupler (1) and clamp (3) from reservoir (2).





3. Drain brake fluid in reservoir.
4. Disconnect clutch reservoir hose from reservoir (M/T model).
5. Disconnect brake pipes (1) connected to master cylinder.
6. Remove master cylinder fixing nuts (2).
7. Remove master cylinder (3) and O-ring.





Installation

1. Install new O-ring (2) to master cylinder assembly (1).
2. Apply grease to piston rod "A". Use specified grease in spare to master cylinder or brake booster as supply parts.
3. Install master cylinder assembly (1) to brake booster (3) and tighten master cylinder fixing nuts to specified torque.

Tightening torque
Master cylinder fixing nut a: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)





4. Connect brake pipe to master cylinder and tighten flare nuts to specified torque.

Tightening torque
Brake pipe flare nut for M10 a: 16 Nm (1.6 kgf-m, 11.5 ft. lbs.)
Brake pipe flare nut for M12 a: 19 Nm (1.9 kgf-m, 14.0 ft. lbs.)





5. Connect clutch reservoir hose to reservoir and install reservoir hose clamp (M/T model).
6. Connect fluid level switch connector and clamp.
7. Fill reservoir with specified brake fluid up to its MAX level.
8. After completing the work, bleed air from brake and clutch system and bleed air from clutch system.
9. Check each installed parts for fluid leakage.
10. Check brake pedal for play.
11. Perform brake test and check fluid leakage.