Disassembly
Caution: Nabuko Cylinder: Remove the master cylinder reservoir only when necessary.
1. Using a flathead screwdriver, pry the retaining cap tabs outward as shown in the illustration and remove the retaining cap.
When removing, hold the cap securely so that the piston does not pop out of the master cylinder.
2. Fix the cylinder body flange in a vise as shown.
Attention:
Insert the master cylinder into a vise with the pin hole facing up.
Lay down the copper plates and cloth so as not to damage the cylinder.
3. Using a punch with a diameter of approx. 4 mm knock out the fixing pin of the tank.
4. Remove the master cylinder assembly from the vise.
5. Remove the reservoir and rubber bushings from the cylinder body.
6. Using a Phillips screwdriver, disconnect the piston and press the piston stopper out of the cylinder body.
7. Carefully, without distortion, to avoid damage to the walls of the cylinder, remove the primary piston assembly.
Cylinder manufactured by Tokiko
Cylinder produced by Nabuko
8. Tap the flange against a piece of wood and release the secondary piston assembly. Carefully, without distortion, to avoid damage to the cylinder walls, remove the secondary piston assembly.
Examination
Check for damage, wear, corrosion and pitting on the inner walls of the cylinder. Replace cylinder if necessary.
Assembly notes
Do not use mineral oils such as kerosene or gasoline, or rubber grease for cleaning and assembly.
Make sure that there are no foreign particles on the inner walls, piston and cylinder seal. Do not damage components with special tools when assembling.
Do not drop components. Do not install components that have fallen.
Assembly
1. Apply Nissan #2500 Brake Fluid or Nissan Tire Lubricant (KRE1200030) on the inner walls of the cylinder body and the contact surface of the piston assembly. Then insert into the cylinder body first the secondary piston assembly and then the primary piston assembly.
Attention:
Do not reuse the primary and secondary pistons.
Pay attention to the installation direction of the piston collar. Insert it without distortions so that it does not touch the inner walls of the cylinder.
Always replace the complete internal parts kit.
2. Visually check the position of the secondary piston slot through the second reservoir opening and install the piston stopper.
Cylinder manufactured by Tokiko
Cylinder produced by Nabuko
Caution: Nabuko Cylinder: Do not reuse piston stop o-ring.
3. Put the stopper cap on the piston. Press the retaining cap until its catches are fully engaged in the grooves on the cylinder body.
Caution: Do not reuse the lock cap.
4. Apply Nissan #2500 Brake Fluid or Nissan Tire Lubricant (KRE1200030) on the rubber bushing, insert it into the master cylinder.
Caution: Do not reuse the sleeve.
5. Secure the cylinder body flange in a vise as shown.
Attention:
Insert the master cylinder into a vise with the pin hole facing up.
Lay down the copper plates and cloth so as not to damage the cylinder.
6. Place the reservoir on the cylinder body as shown. Align the pin holes and install the pin.
Attention:
Do not reuse the reservoir pin and the reservoir itself.
Insert the pin through the hole in the cylinder body from the chamfer side.