Front Disc Brake: Disassembly and Assembly: Assembly

CAUTION: Do not use Rubber Grease when assembling.

Install the bleed valve and cap.
Apply clean brake fluid to the new piston seals (1) and insert the new piston seals (1) into the groove on the cylinder body.

Fig 1: Installing Piston Seals Into Groove On Cylinder Body
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Do not reuse piston seals.
Apply rubber grease to the new piston boots (1). Cover the piston end (2) with the piston boot (1), and then install the cylinder side lip on the piston boot (1) securely into the groove on the cylinder body.

Fig 2: Identifying Piston End And Piston Boot
Courtesy of SUZUKI OF AMERICA CORP.
CAUTION:
- Do not reuse piston boot.
- Press pistons in evenly and vary the pressing points to prevent the cylinder inner wall from being damaged.
Install the pistons (1) into the cylinder body and insert the piston boots (2) side lip into the piston groove as shown in illustration.

Fig 3: Identifying Pistons And Piston Boots
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Press pistons in evenly and vary the pressing points to prevent the cylinder inner wall from being damaged.
Apply rubber grease to the sliding pin boots, then install the new upper sliding pin, lower sliding pin, and sliding pin boots on the torque member.
CAUTION: Upper sliding pin must be replaced at each service.
Install the caliper body on the torque member. Refer to [FRONT BRAKE CALIPER AND DISC ROTOR: REMOVAL AND INSTALLATION ].