Disassembly & Assembly
Disassemble in the order indicated in the illustration. (Scheme 24)
Assemble in the reverse order of removal. Place the Piston Block (49-T033-001A) in the caliper, then blow compressed air through the hole to force the piston out of the caliper. (Scheme 25)
| CAUTION | Blow the compressed air slowly to prevent the piston from suddenly popping out. |
| CAUTION | A metal tool may scratch or nick the seal groove, which could result in a seal leak. |
| CAUTION | Do not use a screwdriver or any other similar tool to pry the piston out of the bore. Piston damage could result. |
Note. Inspect the piston for wear, rust, or pits. If any of these conditions exist, a new piston must be installed.
Note. Remove the piston seal from the brake caliper by using the Seal Removal Pick (49-0208-701A). (Scheme 26)
Scheme 24
Scheme 25
Scheme 26
| CAUTION | If the master cylinder body is damaged, replace the unit as a component. When securing the master cylinder in a vise, tighten only the flange of the master cylinder. |
- Disassemble in the order indicated in the illustration. (Scheme 27)
- Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). NOTE: When assembling stop screw (without ABS), install the new O-ring onto the stop screw. (Scheme 28) Then push the primary piston assembly in fully. Install and tighten the stop screw. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000). NOTE: When assembling stop pin (with ABS), install the secondary piston with the piston hole facing the stop pin. (Scheme 29) Then install the new O-ring onto the stop pin. Install the stop pin. Push and release the secondary piston assembly to verify that it is held by the stop pin. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164090-S17253440532004072100000).
Scheme 27
Scheme 28
Scheme 29
Disassembly & Reassembly
- Remove the rear wheel assembly. Remove rear pads, see «REAR DISC BRAKE PADS»(ref-164090-S12697477632004072600000). Disassemble in the order indicated in the illustration (Scheme 30) CAUTION: Blow the compressed air slowly to prevent the piston from suddenly popping out.
- Place a piece of wood in the caliper, then blow compressed air through the hole to force the piston out of the caliper.
- Remove the piston seal from the brake caliper by using the Seal Removal Pick (49-0208-701A). (Scheme 31)
- Reassemble in the reverse order of disassembly.
Scheme 30
Scheme 31
Disassembly
- Remove the rear wheel assembly. Remove rear brake drum, see «REAR BRAKE DRUM»(ref-164090-S35316196552004072100000) under REMOVAL & INSTALLATION. CAUTION: Do not use denatured alcohol for flushing the brake system or cleaning assemblies where alcohol could be trapped. If denatured alcohol is trapped, it can cause eventual failure of rubber components in the system. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic system. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all new rubber seals and flex hoses must be installed. Use DOT 3 brake fluid.
- Disassemble the rear wheel cylinder. (Scheme 32) Remove the bleeder screw cap. Remove the bleeder screw. Remove the dust boots. Remove the pistons and piston seals. Remove the spring. Disassemble in order listed on illustration.
- Inspect the rear wheel cylinder bore for wear, rust or pits. If any of these conditions exist, install a new wheel cylinder.
Scheme 32
Reassembly
| CAUTION | Always install new piston seals and dust boots when assembling the rear wheel cylinder. Always lubricate the bore with new brake fluid. Use DOT 3 brake fluid. |
To assemble, reverse the disassembly procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .