Honda Insight 2000-2006

Slave Cylinder

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Removal & Installation




WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the clutch system. You should always buy the highest quality brake fluid that is available. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Remove the engine cover and air cleaner housing.
  4.  
  5. Remove the throttle drum cover (A).

    Click image to see an enlarged view

    Fig. Remove the throttle drum cover (A)

  6.  
  7. Disconnect the clutch line (A) from the slave cylinder (B). Plug the end of the line to prevent fluid leakage.
  8.  
  9. Remove the two bolts (C) and the slave cylinder.

    Click image to see an enlarged view

    Fig. View of the clutch line (A), slave cylinder (B) and mounting bolts (C)

  10.  

To install:

  1. Pull back the boot (A) and apply brake assembly lube or suitable grease to the boot and slave cylinder rod (B). Reinstall the boot.

    Click image to see an enlarged view

    Fig. Pull back the boot (A) and apply brake assembly lube or suitable grease to the boot and slave cylinder rod (B)

  2.  
  3. Apply a suitable high temperature grease to the tip of the slave cylinder rod.
  4.  
  5. Install the slave cylinder (A), then connect the clutch line (B). Tighten the mounting bolts to 16 ft. lbs. (22 Nm) and the clutch line to 11 ft. lbs. (15 Nm).
    NOTE
    Make sure the boot is installed on the slave cylinder.



    Click image to see an enlarged view

    Fig. Install the slave cylinder (A), then connect the clutch line (B)

  6.  
  7. Install the throttle drum cover and tighten the retainer to 7.2 ft. lbs. (9.8 Nm).
  8.  
  9. Bleed the clutch hydraulic system, as outlined in this section.
  10.  

 
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