Disassembly and Assembly

DISASSEMBLY
1. REMOVE RESERVOIR
a. Remove the set screw and pull out the reservoir.
Torque:
w/o ABS: 1.5 Nm (15 kgf-cm, 13 inch lbs.)
w/ ABS: 1.7 Nm (18 kgf-cm, 16 inch lbs.)
b. Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE





4. REMOVE 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:
w/o ABS: 8.0 Nm (80 kgf-cm, 69 inch lbs.)
w/ ABS: 10 Nm (100 kgf-cm, 7 ft. lbs.)
5. REMOVE 2 PISTONS AND SPRINGS





a. Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.

HINT: Tape the screwdriver tip before use.

b. Remove the No. 1 piston and spring 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 disassembly, be careful not to damage the rubber lips on the pistons.





c. Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No. 2 piston and spring 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).


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.