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Many of us use aftermarket clutches in our RSX's. There are many brands and disc materials/designs out there but the common fact among most all of them is that they use an upgraded pressure plate in order to apply more clamping force to the disc, which in turn allows the clutch to hold more torque. This is all fine except for one thing: The stock RSX master cylinder was never really designed to see hydraulic pressure greater than the stock Exedy pressure plate which Honda specs out for all K-series motors.

Commonly, someone will install a "Stage-whatever" clutch in their RSX and then a few thousand miles later, "Oh crap! My clutch pedal is on the floor". What invariably has happened is that the seal around the triangular plate of the master cylinder has blown out from the added pressure required to actuate the new, stiffer pressure plate. The solution is to use the master cylinder from either an EM1 or EM2 Honda Civic. Here is a comparison of the two. RSX on the top, Civic on the bottom...



...As you can see, the Civic unit has no triangular plate seal that can blow out and leak. It is a 100% drop-in retrofit to all year RSX's (the slave cylinders, however, are different between '02-'04 and '05-'06). There are several Honda part numbers for this item but the most common one is 46920-S5A-G06.

Also, when installing this master cylinder, if you have an aftermarket pressure plate, it is mandatory to re-adjust the pedal throw. If you just install it as-is, there is a high likelihood that you will roast the clutch disc prematurely. This is due to the fact that aftermarket pressure plates are made stiffer by re-arching the pressure plate fingers to a higher plane than those of a stock pressure plate. So, the stop nut on the clutch pedal must be backed out to compensate for this added height. As a rule, farther out on the pedal pushrod stop nut = "safer" for aftermarket pressure plates.

Good luck and hope this helps.
 
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