Reassembly

BRAKE: BRAKE MASTER CYLINDER:

REASSEMBLY

1. INSTALL BRAKE MASTER CYLINDER KIT (w/o VSC)
(a) Place the master cylinder in the vise.





(b) Apply lithium soap base grycol grease to new No.1 and No.2 piston sub-assembly.
(c) Install the No.2 and No.1 piston sub-assembly.

NOTICE:
- If the piston is inserted at an angle, the cylinder bore could be damaged.
- Be careful not to damage the rubber lips on the pistons.





(d) Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 Nm (100 kgf-cm, 7 ft-lbf)





(e) Push in the piston and install the snap ring with snap ring pliers.
(f) Apply lithium soap base grycol grease to a new O-ring and install the O-ring to the master cylinder.
2. INSTALL BRAKE MASTER CYLINDER KIT (w/ VSC)
(a) Place the master cylinder in the vise.





(b) Apply lithium soap base glycol grease to new No.1 and No.2 piston sub-assembly.
(c) Install the No.2 and No.1 piston sub-assembly.

NOTICE:
- If the piston is inserted at an angle, the cylinder bore could be damaged.
- Be careful not to damage the rubber lips on the pistons.





(d) Insert the No.2 piston with the groove positioning horizontally.
(e) Install the straight pin.





(f) Push in the piston and install the snap ring with snap ring pliers.
(g) Apply lithium soap base glycol grease to a new O-ring and install the O-ring to the master cylinder.
3. INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply lithium soap base glycol grease to the 2 new master cylinder reservoir grommets.
(b) Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assembly.
4. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Install the master cylinder reservoir sub-assembly to the master cylinder with the screw.
5. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Install the brake master cylinder reservoir strainer.
6. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
(a) Install the brake master cylinder reservoir filler cap assembly.
7. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY





(a) Install the master cylinder sub-assembly and 2-way with the 2 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft-lbf)





(b) Using SST, connect the 6 brake lines to the master cylinder sub-assembly.
Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
SST: 09023-00101
(c) Connect the level warning switch connector.
8. FILL RESERVOIR WITH BRAKE FLUID (Service and Repair)

9. BLEED BRAKE MASTER CYLINDER (Service and Repair)

10. BLEED BRAKE LINE (Service and Repair)

11. CHECK FLUID LEVEL IN RESERVOIR (Service and Repair)

12. INSPECT FOR BRAKE FLUID LEAK
13. INSTALL AIR CLEANER ASSEMBLY