Master Cylinder Assembly Disassembly and Assembly: Assembly

NOTE:

See "BRAKES NOTE ".
Before assembling, wash each part in fluid recommended to use for that vehicle and inspect the parts referring to "MASTER CYLINDER ASSEMBLY INSPECTION: ".

Install secondary piston assembly into cylinder.
Install primary piston assembly in cylinder.
Install plate, cylinder cup and piston stopper in that order, refer to the figure of "MASTER CYLINDER ASSEMBLY CONSTRUCTION: " for their correct installation direction.
Depress primary piston assembly by rod (1), and install circlip (2).

Fig 1: Installing Secondary Piston Assembly And Circlip Into Cylinder
Courtesy of SUZUKI OF AMERICA CORP.
Install piston stopper bolt with pistons pushed in all the way and tighten it to specified torque (for vehicle without ABS).
Tightening torque

Piston stopper bolt for (a): 10 N.m (1.0 kg-m, 7.5 lb-ft)

Fig 2: Installing Piston Stopper Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Apply thin coat of brake fluid to all around new grommets (2 pcs.) and install them to cylinder body, then install reservoir (2) to master cylinder (3).
Set a new pin (1) in reservoir hole and drive it in. At this time, make end of pin and end face margin of reservoir equal. Or tighten connector screw to specified torque, refer to "MASTER CYLINDER RESERVOIR REMOVAL AND INSTALLATION: "

Fig 3: Installing Connector Pin Of Master Cylinder Reservoir

Courtesy of SUZUKI OF AMERICA CORP.