User manual HAYES DISC BRAKES MASTER CYLINDER REBUILD

[. . . ] Hint: This is best done with the lever assembly removed from the handlebars and having the lever assembly placed over the open jaws of a vice. Remove the two plastic lever pin bushings from each side of the body. HFX Mag / Mag Plus B. Master Cylinder Rebuild The right hand and the left hand master cylinders will be rebuilt in the exact same manner. [. . . ] DO NOT attempt to take the rubber seals off the mc piston. The cartridge spring and spring guide will also come out of the cartridge. Clean and inspect the inside of the master cylinder and all parts. Replace those parts that are damaged with new service parts. Thoroughly clean all the parts by spaying them with isopropyl alcohol and wiping them with a clean rag. Begin reassembly by dropping the cartridge spring into the cartridge ­ make sure the spring falls directly into the center of the cartridge. Drop the spring guide into the spring with the head up. Note: 2003 model brakes do not use the spring guide. Install the new master cylinder piston into the cartridge over the spring and spring guide. Install the ball end of the threaded push rod into the master cylinder piston. Push on the push rod to assure the spring assembly is lined up correctly. Place the retaining washer over the threaded end of the push rod. Using a snap ring tool, install the snap ring into to the snap ring groove on the inside of the cartridge. Push on the threaded push rod to assure that all parts are properly in place. [. . . ] Note: 2000-2003 Comp, HFX-Mag, and Mag Plus model brake have a flat machined on the threaded end of the aluminum cartridge. 98/99 and DH model brakes DO NOT have a flat machined across the threaded end of the cartridge. With a 13mm wrench, thread the jam nut onto the end of the cartridge and torque the nut to 50 in-lbs +/- 5 in-lbs. [. . . ]