TUG MZ - Section 4: Master Cylinder Disassembly and Assembly; Master Cylinder Removal; Master Cylinder Disassembly; Inspection and Repair

3-4-1
Orig
CD373
Chapter 3
MZ Tow Tractor Section 4
SECTION 4: MASTER CYLINDER DISASSEMBLY AND ASSEMBLY
A. MASTER CYLINDER REMOVAL
Remove master cylinder as outlined below. (When it is necessary to repair the master cylinder during
the warranty period, replace the cylinder as a unit instead of overhauling the cylinder with a service
repair kit.)
1. Open console door.
2. Remove brake lines from cylinder body.
3. Plug brake line ports or drain brake fluid into appropriate container.
4. Remove two (2) mounting bolts and nuts.
5. Slide master cylinder off of push rod.
B. MASTER CYLINDER DISASSEMBLY
1. Clean the outside of the master cylinder and remove the reservoir cover and reservoir
diaphragm. Drain any fluid left in the cylinder. Be careful with brake fluid as it damages
painted surfaces.
2. Remove the snap ring holding the pistons in the cylinder body.
3. Remove the primary piston assembly from the master cylinder. Discard the piston assembly.
WARNING: USE LOW AIR PRESSURE TO REMOVE THE PISTON.
HIGH PRESSURE COULD RESULT IN PERSONAL INJURY AND/OR
DAMAGE TO THE EQUIPMENT.
4. Using an air hose in the rear brake outlet port of the cylinder body, carefully blow the
secondary piston out of the cylinder body. Remove the return spring, spring retainer, cup
protector and cups from the secondary piston. Discard the cup protector and cups.
C. INSPECTION AND REPAIR
1. Clean all parts in clean isopropyl alcohol or Rotunda Brake Parts Washer (model 650016) or
equivalent, and inspect the parts for chipping, excessive wear or damage. Replace them, if
necessary. When using a master cylinder repair kit, use all the parts provided.