Master Cylinder Disassembly/Assembly

Fig. 2 Master Cylinder Retainer Clip Removal:

Fig. 3 Master Cylinder Piston Removal:

Fig. 4 Master Cylinder Piston Assembly:

DISASSEMBLE
1. Wipe reservoir, then remove cap, inspect cap and diaphragm for damage, replace as required.
2. Empty brake fluid reservoir.
3. Remove brake fluid level sensor.
4. With suitable wooden dowel, depress primary piston assembly, then remove clip at end of master cylinder, Fig. 2.
5. Apply low pressure non-lubricated compressed air to upper brake fluid output port located at blind end of master cylinder bore, Fig. 3, to remove primary and secondary piston assemblies, Fig. 4.
6. Clean all parts in clean denatured alcohol, then dry with compressed air.
7. Inspect all parts and cylinder bore for damage, repair or replace as required.

ASSEMBLE
1. Using suitable clean brake fluid, lubricate secondary seal and master cylinder bore.
2. Install spring to master cylinder bore.
3. Install secondary piston assembly, then lubricate primary seal and master cylinder bore.
4. Install primary piston assembly, then while depressing primary piston, install clip.
5. Install brake fluid level sensor, then cap to reservoir.
6. Install master cylinder, then bleed brakes.