Replacing the master brake cylinder

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You will need: TORX T25 wrenches, «at 13», «at 17» …



…special wrench for brake lines «on 10».



1. Remove the tank cap..



2.... and pump out the brake fluid from the reservoir, for example, with a large medical syringe.



3. Remove the battery tray (cm. «Removal and installation of the shelf of fastening of the rechargeable battery»).




4. Disconnect the block from the brake fluid level sensor..



5.... and a hose to the clutch release master cylinder from the brake master cylinder reservoir (cm. «Replacing the reservoir of the main brake cylinder»).

USEFUL ADVICE: Immediately after disconnecting the hose from the tank, plug its hole without lowering the hose down. A certain amount of working fluid will remain in the hose, therefore, after installing the reservoir and connecting the hose to it, it will not be necessary to remove air from the clutch release hydraulic drive.


USEFUL ADVICE: Install a stopper on the tank to prevent dirt from entering it.




6. Unscrew the nuts securing the two pipelines to the brake force regulators, holding the regulators from turning with the second key..




7.... nuts for fastening two pipelines to the main brake cylinder..



8.... and move the pipes aside.

GOOD ADVICE: Shut off the pipelines in any way possible (for example, by putting protective caps on the ends of the valves to release air), to prevent leakage of brake fluid.




9. Turn off two nuts of fastening of the main brake cylinder to the vacuum amplifier...




10.... and remove the master brake cylinder assembly with the reservoir.



11. If there is no reservoir on the new master brake cylinder or it becomes necessary to replace the rubber connecting sleeves of the reservoir, unscrew the screw securing the reservoir to the brake master cylinder..



12.... remove the screw from the reservoir and cylinder holes..




13.... and remove the tank, removing its nozzles from the connecting sleeves.

14. If during operation there was a leak of brake fluid through the connecting bushings, remove the bushings from the openings of the cylinder body.

WARNING: The connecting sleeves must not be reused, replace them with new ones.




15. Using a screwdriver, remove the rubber o-ring from the main brake cylinder housing.

WARNING: Replace the sealing ring of the master cylinder with a new one each time the connection is disassembled.


16. Install the brake master cylinder in the reverse order of removal, fill in brake fluid and bleed air from the system (cm. «Bleeding the hydraulic drive of the brake system»).







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