Gilera Nordwest, Workshop Manual

Page: 94 / 136

MASTER CYLINDER
Removal
Drain the brake fluid.
Disconnect the brake pipe by loosening the connecting nut.
Pay attention that the brake fluid does not come in contact with painted, plastic
or rubber parts. When operating on brake system, always protect the above
parts.
When removing the brake pipe, in order to avoid any fluid leakage, close the
pipe end and secure it.
Remove the pipe lever.
Disconnect the stop light switch connector, then remove the master cylinder.
Remove the piston protection from the master cylinder.
Remove the securing seeger ring, then remove piston and spring.
Using the brake fluid, clean the master cylinder inside, fluid tank, spring and
piston.
Check
Check that the master cylinder piston and cylinder don’t presents any linings
(fig. 30).
Piston outer diameter (fig. 31).
Wear limit allowable: 0.05 mm.
Prior to reassembly, check that the seals are not damaged.
Warning
Piston, master cylinder body and spring are not available as separate parts.
Installation
Prior to reassembly, moisten the parts using the brake fluid.
In order to not reverse the seal lips, fit carefully the seals.
Insert the piston in master cylinder.
Fit the protection.
Fit the brake lever and stop light switch connector.
Fit the brake master cylinder on the handlebar.
Connect the brake pipe to the connection, tightening to the appropriate torque.
Fill the tank with DOT 4 brake fluid and bleed the hydraulic system.
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