Disassembly and Reassembly

DISASSEMBLY
1. REMOVE RESERVOIR
a. Remove the set screw and pull out the reservoir.
Torque: 1.7 Nm (17.5 kgf-cm, 15.2 inch lbs.)
b. Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. w/o TRAC:
a. Place the cylinder in vise.





b. Remove the piston stopper bolt.
Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket.

HINT: Tape the screwdriver tip before use.

Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)





c. Remove the 2 pistons and spring.
1. Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.

HINT: Tape the screwdriver tip before use.

2. Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle.

NOTICE:
^ If pulled out and install at an angle, there is a possibility that the cylinder bore could be damaged.
^ At the time of reassembly, be careful not to damage the rubber lips on the pistons.





3. Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the blocks until the piston drops out of the cylinder.

HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 inch).





4. w/ TRAC:
Remove the 2 piston and springs.
1. Push in the piston with a screwdriver, and remove the 2 straight pins by turning over the cylinder body.

HINT: Tape the screwdriver tip before use.

2. Remove the 2 piston and springs by hand, pulling straight out, not at an angle.

NOTICE:
- If pulled out and installed at an angle, there is a possibly that the cylinder bore could be damaged.
- At the time of reassembly, be careful not to damage the rubber lips on the pistons.





HINT: Insert the pistons with elliptic hole facing vertically.

INSPECTION

HINT: Clean the disassembled parts with compressed air.

1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows. Diagrams