Disassembly

BRAKE: BRAKE MASTER CYLINDER:

DISASSEMBLY

1. DRAIN BRAKE FLUID

NOTE: Wash brake fluid off immediately if it adheres to any painted surface.

2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Disconnect the level warning switch connector.

(b) Using SST, disconnect the 6 brake lines from the brake master cylinder.
SST: 09023-00101

(c) Remove the 2 nuts, and pull out the 2-way and brake master cylinder sub-assembly.
4. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
(a) Pull out the master cylinder reservoir filler cap assembly.
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Pull out the master cylinder reservoir strainer.
6. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Remove the screw and pull out the master cylinder reservoir sub-assembly.
7. REMOVE MASTER CYLINDER RESERVOIR GROMMET
(a) Remove the 2 master cylinder reservoir grommets.
8. REMOVE BRAKE MASTER CYLINDER KIT (w/o VSC)
(a) Place the master cylinder in the vise.
(b) Remove the O-ring.

(d) Push in the piston and remove the piston stopper bolt and gasket.
(e) Remove the No.1 piston sub-assembly, pulling straight out not at an angle.

NOTE: If pulled out at an angle, the cylinder bore could be damaged.

(f) Place a shop rag and 2 wooden blocks on the work table and lightly edge until the No.2 piston sub-assembly drops out of the cylinder.

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

NOTE: If pulled out at an angle, the cylinder bore could be damaged.

9. REMOVE BRAKE MASTER CYLINDER KIT (w/ VSC)
(a) Place the master cylinder in the vise.
(b) Remove the O-ring.

(d) Push in the piston with a screwdriver, and remove the straight pin by turning the cylinder body.

HINT: Tape the screwdriver tip before use.

(e) Remove the No.1 and No.2 piston sub-assembly and 2 springs by hand. Pull them straight out, not at an angle.

NOTE: If pulled out at an angle, the cylinder bore could be damaged.