8 CLUTCH 9. MASTER CYLINDER 9A. DISMANTLING OF MASTER CYLINDER (Fig. 6) ● Pull back dust cover. (14) ● Remove circlip retaining push rod (12) ● Remove push rod with retaining washer (11) ● Remove plunger (10) and valve assembly from body by lightly tapping the body on wooden block. ● Using a screw driver, lift the leaf of spring retainer (8). Remove spring assembly from plunger. ● Compress spring (6) to free valve stem (7) from eccentrically positioned hole in the end face of spring retainer. This will separate spring retainer from valve stem. ● Remove spring, valve spacer (5) and spring washer (4) from valve stem. ● Carefully remove valve seal (3) from valve stem. ● Carefully remove gland seal (9) from plunger. 9B. INSPECTION AND ASSEMBLY OF MASTER CYLINDER (Fig. 6) ● Examine bore of body. If it is not scored, ridged or corroded, do not replace. If there is damage in the bore, the cylinder assembly should be replaced. Even otherwise if the clearance between plunger and the bore exceeds 0.13 mm, the assembly should be replaced. ● Examine plunger for rust, burrs and ridges, Replace if necessary. ● Fit new gland seal on plunger such that it fits squarely in plunger groove. ● Fit new valve seal on valve stem with the smallest diameter leading. ● Assemble spring washer on valve stem such that it bends away from valve shoulder. ● Now assemble valve spacer on valve stem. Hold the spacer between fingers such that the valve stem hangs down vertically. Pull the stem downwards as far as possible. Release the stem. Observe whether the valve stem has moved freely upwards. If movement is not free replace valve spacer. ● Install spring over valve stem behind valve spacer, followed by spring retainer. Compress spring and locate valve stem end in key hole slot of spring retainer. ● Fit spring assembly on plunger assembly and lock the leaf of spring retainer by pressing it with nose pliers. ● Lubricate bore of body with brake fluid and dip plunger valve assembly in it. Insert the assembly into bore with valve end leading. ● Check condition of dust cover. If necessary replace. ● If disturbed, adjust push rod length with fork to specified value. ● Place push rod with retaining washer on plunger and fit circlip for retaining push rod in the body groove. ● Fit dust cover on body. 10. SLAVE CYLINDER 10A. DISMANTLING OF SLAVE CYLINDER (Fig.7) ● Remove circlip (4) and washer (2). ● Remove dust cover (3). ● Remove plunger (5) with gland seals and plunger spring (7) from body by lightly tapping it on wooden block. ● Remove gland seals from plunger. 10B. INSPECTION AND ASSEMBLY OF SLAVE CYLINDER (Fig.7) ● Examine bore of body. If it is not score, ridged or corroded do not replace. If there is doubt about condition of bore, then it should be replaced with new slave cylinder assembly. Even otherwise if the clearance between the plunger & bore exceeds 0.13 mm. the assembly should be replaced. ● Examine plunger for rust, burrs, and ridges, Replace if necessary. ● Fit new gland seals on plunger such that it fits squarely in plunger groove. ● Fit small end diameter of spring to plunger. ● Lubricate bore of body with brake fluid and dip plunger assembly in it. Insert plunger assembly into bore with bigger end diameter of spring leading. ● Fit washer over push rod and place it over plunger as shown. Fit circlip. ● Check condition of dust cover. If necessary replace. ● Slide dust cover over body. ● Ensure the push rod length from the slave cylinder mounting face is as shown in sketch.
RkJQdWJsaXNoZXIy MTIwNTUz