Clutch master cylinder.
1 - tank cover, 2 - working fluid tank, 3 - nut, 4 - cylinder body, 5 - piston, 6 - retaining ring, 7 - rod assembly with fork, 8 - pin, 9 - washer, 10 - cotter pin.
Withdrawal
1. Drain the clutch fluid through the bleeder port.
2. Remove cotter pin, pin and washer.
3. Disconnect the hydraulic drive tube from the clutch master cylinder.
4. Turn away a bolt of fastening of the main cylinder.
- Tightening torque: 8-12 Nm
5. Remove the clamps of the hydraulic clutch tube.
6. Having fixed the clutch hose nut, unscrew the tube fastening nut.
- Tightening torque: 12-16 Nm
7. Remove the retainer from the clutch hydraulic hose, then disconnect the hose from the bracket.
8. Remove the clutch hydraulic pipe.
9. Disconnect the clutch slave cylinder tube.
Disassembly
1. Remove the piston retaining ring.
2. Remove the stem and piston assembly.
Note:
- Be careful not to damage the piston assembly and master cylinder body.
- Do not disassemble the clutch master cylinder piston.
3. If necessary, remove the reservoir cap, reservoir clamp and clutch fluid reservoir.
Examination
1. Check the inner surface of the master cylinder body for rust, corrosion (pitting) and badass.
2. Check the piston cover for wear and deformation.
3. Check the piston for rust, corrosion (pitting) and badass.
4. Check the clutch hydraulic tubes for clogging.
5. Measure the inner diameter of the master cylinder with a bore gauge and the outer diameter of the piston with a micrometer.
Note: having installed the inside gauge in the master cylinder, measure the diameter in three sections by moving the inside gauge in the axial direction. Then turn the caliper 90°and repeat the operation. All six values obtained must meet the technical data.
- Rated value: 15.87 mm
6. Measure the outer diameter of the piston with a micrometer and calculate the clearance between the piston and the master cylinder body (the difference between the inner diameter of the master cylinder and the outer diameter of the piston).
If the clearance exceeds the limit, replace the master cylinder and/or piston assembly.
- Limit value: 0.15 mm
7. Check the hydraulic clutch hose or tube for cracks, damage or blockage.
Assembly
1. Assembly is carried out in the reverse order of disassembly.
2. When assembling, apply working fluid to the inside surface of the clutch master cylinder body and to the outside surface of the piston.
- Fluid type: SAE J 1703 brake fluid (DOT3)
Installation
1. Installation is in the reverse order of removal, the tightening torques of the bolts and nuts are indicated in the text of the description of the removal procedure.
2. When connecting the stem yoke to the clutch pedal, apply grease to the pin and washer in the clutch pedal joint.
- Lubrication: SAE J310, NLGI #2 hub bearing grease
3. After installation, bleed the clutch release drive.