Brake Master Cylinder Reassembly
NOTE:
  • Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
  • Before reassembling, check that all parts are free of dirt and other foreign particles.
  • Replace parts with new ones whenever specified to do so.
  • Use only genuine Honda DOT 3 or DOT 4 Brake Fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system.
  • Replace the master cylinder if the bore is damaged or worn. Do not hone or attempt to refinish the bore.
  • Coat the piston cups, pressure cup and master cylinder bore with clean brake fluid.
  • Use recommended greases in the master cylinder seal set.
  • When you apply the silicone grease, make sure not to adhere to the terminal part of connectors and surrounding switches. Also do not touch the switches and the terminal part of connector by hands or glove that adheres the silicone grease.
  • The illustration shows LHD model.
  1. Coat the cups (A) of a new primary piston (B) with clean brake fluid, then install the primary piston into the master cylinder.
    NOTE: Check that the valve stem (C) moves smoothly by lightly pushing it through the slot in the piston.
  1. Coat the cup (A) of a new secondary piston (B) with clean brake fluid, and apply the silicone grease to the piston surface (C).
  1. Apply the rubber grease to a new piston guide (A), a new O-ring (B) and a new secondary cup (C).
  1. Install the primary piston (A), the secondary piston (B) and the piston guide (C) into the master cylinder. Make sure the direction of piston guide.
    NOTE: Install the primary piston so the slot (D) in the piston aligns with the stop pin hole in the master cylinder.
  1. Install the reservoir seal (A) to the reservoir cap (B).
  1. Install the strainer (C) and the new grommets (D) to the reservoir (E).
  1. Align the slot (A) in the primary piston with the stop pin hole (B) by pushing the secondary piston in, and install the stop pin (C).
  1. Install the reservoir (D) to the master cylinder.
  1. Install the new circlip (A) while pushing in the secondary piston (B). Be careful not to scratched damage on the piston surface with the circlip edges.