Sym GTS 250 Service Manual page 171

14. Brake System
Remove the rubber pad.
Remove the cir clip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Master Cylinder Inspection
Check the master cylinder for damage or scratch.
Replace it if necessary.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit:
Front brake: 11.055 mm
Rear brake: 14.055 mm
Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.
Allowable limit:
Front brake: 10.945 mm
Rear brake: 13.945 mm
Master Cylinder Assembly
Caution
 It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
 Make sure there is no dust on all
components before assembling.
Apply clean brake fluid to the piston cup, and then
install the cup onto the piston.
Install the larger end of the spring onto the master
cylinder.
The master cup's cavity should be face inside of
master cylinder when installing the master cup.
Install the cir clip.
Caution
 Never install cup lip in the opposite direction.
 Make sure the cir clip is seated securely in
the groove.
Install the rubber pad into groove properly.
14-10
To this chapter contents
Rubber
boot
cup
Rubber
boot
cup
Cir clip
Piston
Piston
Spring
Master cylinder
Master cylinder
Master cylinder piston
Cir clip
Piston
Piston
Spring
Master cylinder