Note: Wash all parts in brake fluid and air dry; blow out all holes with compressed air.
 |
 |
Before reassembling, check that all parts are free of dirt and other foreign particles.
If necessary, replace the parts with new ones.
Use only genuine Honda DOT 3 or DOT 4 brake fluid. Using brake fluid other than that specified for Honda vehicles may cause corrosion of components and reduce the life of the system.
Do not mix different brands of brake fluid as they may be incompatible.
Replace the master cylinder if the cylinder bore is damaged or worn. The cylinder bore cannot be honed or finished.
Lubricate all piston seals, grease fittings and the inner walls of the master cylinder with clean brake fluid.
Use the recommended lubricant from the master cylinder repair kit.
1. Insert the tank seal into the groove on the tank lid.
2. Install the mesh filter and tank cover assembly onto the tank.
3. Lubricate the seals A of the new primary piston B with clean brake fluid, then insert the primary piston into the master cylinder.
Note: Check that valve C moves smoothly in the piston groove when pressed lightly.
4. Lubricate the seal A of the new secondary piston B with clean brake fluid, then apply silicone grease to the surface of piston C.
5. Apply rubber grease to the new piston guide A, sealing ring B and additional cuff C.
6. Install the primary piston A, secondary piston B and piston guide C into the master cylinder. Do not confuse the direction of the piston guide.
Note: Install the primary piston into the D hole of the master cylinder so that the slot in the piston aligns with the pin hole.
 |
 |
7. Align the groove A of the primary piston with the hole for the end pin B by pressing the secondary piston into the cylinder, then install the end pin C.
8. Apply rubber grease to the surface of the new expansion tank coupling bushings D, then install them and the expansion tank block E onto the master cylinder.
9. Install the new snap ring A by pressing the secondary piston B inward. When installing the snap ring, be careful not to scratch the surface of the secondary piston.
10. Install tank A and hose B onto expansion tank block C.
Note: Align the D marks on the tank and expansion tank block with the E mark on the hose.
Set the direction of the clamps F.
11. Lubricate the new rod seal with silicone grease from the master cylinder repair kit and install the seal into the master cylinder.