Lotus Elise S1 Service Notes page 474

Section QF
Note that no pedal downstop is fitted, and that the pedal will contact the pedal box before the master
cylinder 'bottoms out'.
Adjusted as above, full pedal travel should produce a slave cylinder pushrod movement of 13 -15 mm. If
this is not achieved, bleed the hydraulic system using new DOT 4 non-mineral type fluid.
Note that the alloy trunnion in the pedal is Zylan coated to provide maintenance free lubrication, although
silicone grease is used on initial assembly.
QF.3 - HYDRAULIC RELEASE SYSTEM
Master Cylinder
The 5/8" (15.9 mm) bore master cylinder is mounted on the pedal box, and is accessible from within the
front services compartment. The cylinder is not equipped with its own fluid reservoir, but instead is linked via
hose to the adjacent brake fluid reservoir.
Input
pushrod Pedal
Brake master
cylinder reservoir
Fluid reservoir
hose
Outlet
pipe
Fixing
Clutch master
cylinder
To replace the master cylinder:
Clean the master cylinder and surrounding area with methylated spirit Do not use petrol or paraffin.
Take all necessary precautions to guard against contamination of painted surfaces with brake fluid.
Disconnect and immediately plug and cap the hose connection to the fluid reservoir, and the output pipe
connection.
From inside the footwell, remove the two bolts securing the cylinder to the pedal box. Withdraw the
cylinder from the front services compartment.
To refit, reverse the removal procedure, taking care to feed the pedal pushrod through the dust boot and
into the end of the master cylinder as the cylinder is positioned. Tighten the outlet pipe connection to 20 - 24
Nm and bleed the hydraulic system of air.
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1998 / 02