SAFARI

BRAKES

OVERHAULING OFTANDEM MASTER CYLINDER

Master cylinder should be overhauled as per

recommended service schedule during overhaul, all

internal parts including plungers and springs should

be replaced with genuine parts provided in the kit.

Subsequently, if the condition of the bore is

satisfactory fur ther overhauling should be

undertaken, or else, the whole cylinder should be

discarded and fitted with new assembly.

REMOVAL OF TANDEM MASTER CYLINDER

Connect a transparent (Vinyl) bleed tube to one of

the rear wheel cylinder’s bleed screw and drain the

fluid into a container by pumping the pedal, from the

primary circuit. Repeat the same by connecting the

bleed tube to one of the front wheel cylinder’s bleed

screws and collect the fluid from the secondary

circuit. Disconnect all outlet pipes from the master

cylinder. Fig. 31. Loosen master cylinder mounting

nuts and remove the same.

DISMANTLING OF TANDEM MASTER CYLINDER

Fig. 32

Clean the tandem master cylinder assembly

externally with alcohol or fresh brake fluid before

dismantling it. Hold the fluid reservoir and by rocking

it on either side, lift the same out of the grommets

in the tandem master cylinder. Remove both the

grommets from the master cylinder body using a

connector screw driver with blunt edge. Remove

the ‘O’ ring fitted in the groove on the mounting flange

with a blunt edge pin. Remove the residual pressure

valve from the primary outlet port. Slightly push the

primary plunger with a round rod, hold it in depressed

position and remove the stop pin with gasket.

Without removing the stop pin, if any attempt is

made to dismantle the tandem master cylinder, the

secondary plunger, cannot be removed. Remove the

adaptor from the secondary outlet.

Then, clamp the cylinder (housing) in a vice with

soft jaws. With the help of circlip plier, remove the

circlip. Remove the complete primary plunger

assembly out of the bore. Remove the stop washers

intermediate ring and the primary back seals out

from the shaft of the primary plunger. Remove the

cylinder from the vice. Tap the cylinder, bore facing

downwards, on a wooden block to allow the

secondary plunger and the return spring to slide out

of the bore.

Clean the cylinder bore in fresh brake fluid or alcohol

and blow with compressed air. Be sure that the four

holes (two cut off holes and two feed holes visible

through the primary and secondary inlet ports) in the

cylinder body are clean, by blowing dry compressed

air. Do not poke the holes with sharp instrument. Blow

breather hole at the flange and make sure it is clear.

INSPECTION OF TANDEM MASTER CYLINDER :

Examine the bore of the tandem master cylinder. If it

is not scored, ridged or corroded and is smooth to the

touch, the master cylinder can be reassembled using

the appropriate parts from the repair kit. If there is

slightest doubt about the condition of the bore like

having deep grooves or pitting marks, there is no other

way than to fit a new master cylinder assembly.

If contamination is observed in the removed seals

(normally they would have swollen and can be

compared with new seals from the kit which will tell

clearly that the size is enlarged), the entire system,

i.e. wheels cylinder rubber parts including both front

and rear hoses must be discarded and the entire

system should be flushed.

CAUTION :

Do not use kerosene (or) petrol (or) any other mineral

oils to clean the cylinder and its internal parts. As it

will lead to contamination and damage of rubber parts.

Clean all dismantled par ts with alcohol or

recommended fresh brake fluid only.

Fig. 31