Replacing the reservoir of the main brake cylinder

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You will need a TORX T25 key.

1. Disconnect a wire from the minus plug of the storage battery.



2. Remove the decorative engine cover (see Removal and installation of a decorative casing of the engine).

3. Remove the air filter (refer to Removing and installing the air filter and intake silencer).



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



5. Remove the battery (see Removing and installing the battery) …




6.... and a shelf for its fastening along with an intake silencer (refer to Removing and Installing the Battery Shelf).



7. Press the clamp of the brake fluid level sensor wiring harness block..



8.... and disconnect the block from the sensor.



9. On a vehicle with a manual transmission, squeeze the clamps on the hose end (shown in the photo with an arrow) to the clutch master cylinder and disconnect the hose from the brake master cylinder reservoir.


USEFUL ADVICE: Immediately after disconnecting the hose from the tank, plug its hole without lowering the hose down. There will be some working fluid left in the hose, so after installing the tank and attaching the hose to it, it will not be necessary to remove air from the clutch release hydraulic drive.


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

NOTE: On a vehicle with an automatic transmission, the master cylinder reservoir fitting has a spring loaded plug instead of the hose end. There is no need to remove it unless necessary.




10. Turn out the screw of fastening of a tank to the main brake cylinder.

11. Remove the tank, removing its branch pipes from the connecting sleeves.



12. If during operation there was a leak of brake fluid through the connecting sleeves, remove the sleeves from the holes in the cylinder body.


NOTE: Shown with master cylinder removed for clarity.


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


13. Before installing the tank, insert the connecting sleeves into the holes of the main brake cylinder. Then install the tank, inserting its nozzles into the connecting sleeves by hand until it stops, and fix it with a screw (see point 10).

USEFUL ADVICE: To facilitate the installation of connecting sleeves into the cylinder and reservoir pipes into the sleeves, moisten them with fresh brake fluid.


14. Fill in the brake fluid and bleed the air from the hydraulic drive (see Bleeding the hydraulic brake system).







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