AP Racing Catalogue Issue 4

visit www.apracing.com for installation drawings & up to date product range details 72 CP7198, CP7398 & CP9093 REPAIR KITS Repair kit information for CP7198, CP7398 and CP9093 Master cylinders is tabled below for all bore sizes. Please follow the instructions given. INSTRUCTIONS A) Remove inlet (19) , gasket (18) , boot (16) and depress push- rod >5mm (13) into body. B) Remove stop pin (17) and circlip (15) . C) Carefully remove internal components from body. D) Remove internal circlip (3) and cut-off components from end of piston (11) . E) Replace the following (Making sure all seals have been lubricated with Brake Fluid). Primary seal (9) , Piston Washer (10), Cut-off Pin Seal (6) , Internal circlip (3) , Secondary seal (12) and Inlet Gasket (18) . (Care must be taken when fitting seals as damage may occur from fitting tools or over- stretching). F) Reassemble cut off components into end of piston (11) and secure with new internal circlip (3) . G) Check bore is free from debris. H) Lubricate bore with Brake Fluid. I) Reassemble internal components into body (1) ensur- ing piston slot is orientated vertically and depress piston (11) >5mm into body beyond its assembled position as shown on the drawings. (Depressing the piston is important to avoid damage to the internal cut-off pin (7). J) Screw in stop pin (17), with piston still depressed, with a tightening torque of 3.5Nm (2.6lbsft), and assemble pushrod (13) and stop washer (14) . K) Use new circlip (15) to secure internal components and new boot (16) to protect from debris. L) Reassemble new inlet gasket (18) and inlet (19) and tighten with a tightening torque of 67Nm (50lbsft), ensuring inlet is clean of any debris. MASTER CYLINDER - Repair Kits CP6467 REPAIR KITS Repair kit information for CP6467 Master cylinders is tabled below for all bore sizes. Please follow the instructions given. INSTRUCTIONS 1) Remove rubber boot (18) and un-screw end cap (14) . 2) Carefully remove internal components and un-screw valve cap (3) . 3) Carefully remove centre valve components. 4) Replace the following. (Making sure all seals have been lubricated with Brake Fluid). O-Ring Valve Cap Seal (4) , Centre Valve Seal (9) , Piston Washer (10) , Primary Seal (11) , O-Ring End Cap Seal (15) , D-Section Piston Seal (16) and Slydring Bearing (17) . (Care must be taken when assembling seals, as damage may be caused). 5) Check bore is free from debris. 6) Lubricate bore with Brake Fluid. 7) Reassemble valve seal components into piston (2) . 8) Use original valve cap (3) to secure centre valve components. Tighten to 5Nm (3.7lbsft) and use Loctite threadlocker 242 or 243. 9) Reassemble internal components into body. 10) Use original end cap (14) to secure internal components. Tighten to 24Nm (18lbsft) and use Loctite threadlocker 242 or 243. 11) Fit new boot (18) to protect from debris. Ref. Description Included in Repair Kit 1. Body 2. Piston 3. Valve Cap 4. O-Ring, Valve Cap Seal Yes 5. AKB Plug 6. Sleeve 7. Spring 8. Valve Piston 9. Centre Valve Seal Yes 10. Piston Washer Yes 11. Primary Seal Yes 12. Piston Stop 13. Return Spring 14. End Cap 15. O-Ring, End Cap Seal Yes 16. D-Section Piston Seal Yes 17. Slydring Bearing Yes 18. Boot Yes 19. Lock Nut M8x1.25 Bore Size Repair Kit Part Number 14.9mm CP6467-149RK 16.2mm CP6467-162RK 17.3mm CP6467-173RK 18.8mm CP6467-188RK 20.2mm CP6467-202RK 21.2mm CP6467-212RK 21.8mm CP6467-218RK 23.7mm CP6467-237RK 25.4mm CP6467-254RK 17 16 15 14 6 SLEEVEFITTED WITHCP6467-117 MASTERCYLINDER MASTERCYLINDER WITHCP6467-116 AKBPLUGFITTED 5 8 7 9 3 4 8 4 3 5 7 9 6 11 10 19 14 18 13 12 2 1 Ref. Description Included in Repair Kit 1. Body 2. Piston Return Spring 3. Internal Circlip YES 4. Flow Restrictor 5. Cut-off Pin Spring 6. Cut-off Pin Seal YES 7. Cut-off Pin 8. Spring Retainer 9. Primary Seal YES 10. Piston Washer YES 11. Piston 12. Secondary Seal YES 13. Pushrod 14. Stop Washer 15. Circlip YES 16. Boot YES 17. Stop Pin 18. Inlet Gasket YES 19. Inlet Bore Size Repair Kit Part Number 14.0mm CP7198-88RK 15.0mm CP7198-89RK 15.9mm (0.625”) 5/8” CP7198-90RK 16.8mm CP7198-905RK 17.8mm (0.70”) CP7198-91RK 19.1mm (0.75”) 3/4” CP7198-92RK 20.6mm (0.812”) 13/16” CP7198-93RK 22.2mm (0.875”) 7/8” CP7198-94RK 23.8mm (0.937”) 15/16” CP7198-95RK 25.4mm (1.00”) CP7198-96RK 14 1 2 19 18 17 13 15 16 12 11 9 10 3 4 5 6 7 8 3 4 5 6 7 8 WARNING, IF PISTON IS NOT DEPRESSED WHEN STOP PIN 17 IS FITTED, CUT-OFF PIN 7 WILL BE DAMAGED ENSURE PISTON SLOT IS ORIENTATED VERTICALLY IMPORTANT BEFORE FITTING STOP PIN 7 DEPRESS PISTON 11 >5mm DOWN THE BORE FROM ITS FULLYASSEMBLED POSITION AS SHOWN. THIS IS IMPORTANT TO PREVENT DAMAGE TO CUT-OFF PIN 7 >5.00mm