NOTE
Never install a used piston assembly or spring.
1. See Figure 1. Lightly lubricate piston bore and OD of piston seals with DOT 4 BRAKE FLUID.
2. Install new pushrod/piston assembly (21).
3. Install new seal (2).
4. If necessary, lightly lubricate piston bore and OD of piston seals with DOT 4 BRAKE FLUID. Install new grommet (22) and circlip (23).
5. Install master cylinder reservoir.
a. If necessary, lightly lubricate piston bore and OD of piston seals with DOT 4 BRAKE FLUID. install new o-rings (8, 9).
b. If necessary, install anti bubble button (5).
c. Install master cylinder reservoir (7).
d. Install reservoir screw (6). Tighten.
Torque: 16–18 N·m (12–13 ft-lbs) Brake master cylinder reservoir screw
e. Install gasket (4).
f. Install baffle (3).
g. Install cover (2).
h. Install screws (1). Tighten.
Torque: 1–1.2 N·m (9–11 in-lbs) Brake master cylinder cover screws
6. If necessary, install adjuster.
a. Install adjuster (18) and spring washer (17).
b. Install retainer ring (15).
7. Install brake lever.
a. Install bushing (19).
b. Install brake lever (16) and spring (14).
c. Install pivot pin (24).
d. Install nut (13). Tighten.
Torque: 5–7 N·m (44–62 in-lbs) Brake lever pivot pin nut
8. If necessary, install brake switch (11) and screw (12).
1Cover screw (3)
2Cover
3Baffle
4Gasket
5Anti-bubble button
6Reservoir screw
7Master cylinder reservoir
8O-ring
9O-ring
10Master cylinder mounting bracket
11Brake switch
12Screw
13Nut
14Spring
15Retaining ring
16Brake lever
17Spring washer
18Adjuster
19Bushing
20Dust boot
21Pushrod/Piston assembly
22Grommet
23Circlip
24Pivot pin
Figure 1. Front Brake Master Cylinder Assembly