Master Cylinder Assembly Disassembly and Assembly: Assembly

CAUTION:

Never use any mineral oil such as kerosene oil and gasoline when washing and assembling parts.
Check inside of cylinder wall, pistons and cup seals are free from any foreign objects such as dust and dirt and use case not to cause any damage with a tool during assembly.
Do not drop parts. Do not use any part which has been dropped.

Apply brake fluid to inside of cylinder and contact surface of piston assembly (new piston cups, new cylinder cup).
Install secondary return spring and secondary piston (1) into cylinder body (4).
NOTE: For vehicles equipped with ABS, align oblong hole in secondary piston (2) with stopper pin hole (3) in master cylinder body (4) when installing it.

Fig 1: Installing Secondary Return Spring And Secondary Piston
Courtesy of SUZUKI OF AMERICA CORP.
Install primary piston assembly into cylinder body.
Install piston stopper bolt (1) or stopper pin (2) with pistons pushed in all the way and tighten or install it.
Tightening torque

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

Fig 2: Installing Piston Stopper Bolt And Stopper Pin
Courtesy of SUZUKI OF AMERICA CORP.
Install circlip (1).

Fig 3: Installing Circlip

Courtesy of SUZUKI OF AMERICA CORP.