Front Disc Brake Caliper Disassembly and Assembly: Assembly

Assemble parts in reverse order of disassembly, observing the following instructions.

CAUTION:

Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.
Never use other fluid or thinner.
Before installing piston seal or cylinder boot to cylinder, apply grease to them.
Install a new piston seal into groove in cylinder securely making sure that it is not twisted.
Before installing caliper to carrier, install slide pin with grease applied into caliper carrier hole and check for its smooth movement in thrust direction.
After reassembling brake lines, bleed air from them.

Fig 1: Removing Piston Seal
Courtesy of SUZUKI OF AMERICA CORP.
Install piston seal, boot, piston and retaining ring to caliper referring to the following instructions.

Replace with a new piston seal (1) at every overhaul. After applying grease, fit piston seal (1) into groove in cylinder taking care not to twist it.

Fig 2: Checking Slide Pin Operation
Courtesy of SUZUKI OF AMERICA CORP.
Before inserting piston (2) into cylinder, apply grease to new boot (1) and install it onto piston as shown.
"A": 1-grooved side directed cylinder side

"B": 2-grooved side directed pad side

Fig 3: Installing Piston Seal
Courtesy of SUZUKI OF AMERICA CORP.
Fit boot as it is in figure into boot groove in cylinder with fingers.

Fig 4: Identifying Piston Installation Piston
Courtesy of SUZUKI OF AMERICA CORP.
Insert piston into cylinder by hand and fit boot in boot groove in piston.
NOTE: Check that boot is fitted in boot groove securely all around piston and cylinder.

Fig 5: Fitting Boot Into Boot Groove In Cylinder
Courtesy of SUZUKI OF AMERICA CORP.
Install cylinder boot retaining ring (2) to cylinder boot (1) as shown in figure.
CAUTION: Use care not to cause damage to cylinder boot.

Fig 6: Inserting Piston Into Cylinder
Courtesy of SUZUKI OF AMERICA CORP.