Master Cylinder Assembly

CAUTION: Do not use abrasives in the master cylinder bore. Abrasives can damage the bore.

CAUTION: Rubber parts and retaining rings must be discarded and replaced with new parts.

Clean all the parts with denatured alcohol or clean brake fluid. Dry the parts with compressed air.
Inspect the master cylinder bore for scoring or corrosion. If scoring or corrosion is evident, replace the master cylinder body.
Lubricate the master cylinder bore with clean brake fluid.

Fig 1: Locating Master Cylinder Bore
Courtesy of SUZUKI OF AMERICA CORP.
Carefully insert the secondary piston assembly bore until the secondary piston contacts the base of the cylinder body. Use a wood or a plastic drift, if necessary.
Insert the primary piston assembly and the washer.

Fig 2: Installing Primary Piston Assembly And Washer
Courtesy of SUZUKI OF AMERICA CORP.
Press the pistons into the cylinder bore using a wooden or a plastic drift.
Insert the washer and the new retaining ring into the groove in the cylinder bore.
CAUTION: When installing the washer and the new retaining ring, take care not to damage the cylinder bore.

Fig 3: Installing Washer And New Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install the retaining screw in the bottom of the master cylinder and tighten it until it bottoms out on the internal piston assembly.

Fig 4: Installing Retaining Screw In Bottom Of Master Cylinder
Courtesy of SUZUKI OF AMERICA CORP.
Insert a new O-ring over the cylinder body.
Install the brake fluid reservoir. Refer to "BRAKE FLUID RESERVOIR INSTALLATION ".
Install the master cylinder. Refer to "MASTER CYLINDER ASSEMBLY INSTALLATION ".
Raise and suitably support the vehicle.
Bleed the brake system. Refer to "MANUAL BLEEDING THE BRAKES ".
Lower the vehicle.

Fig 5: Inserting O-Ring Over Cylinder Body
Courtesy of SUZUKI OF AMERICA CORP.