Master Cylinder Disassembly and Assembly: 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 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 (the non-ABS master cylinder is shown) with clean brake fluid.
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.

Fig 1: Inserting Primary Piston Over Secondary Piston In Cylinder Bore
Courtesy of SUZUKI OF AMERICA CORP.
Press the pistons into the cylinder bore using a wooden or a plastic drift.
Insert the new retaining ring into the groove in the cylinder bore (the non-ABS cylinder body is shown). Remove the welding rod.
Move the pistons backward and forward after installation to check for free movement.
See Figure.
Lubricate the seal ring and insert the seal into the cylinder bore. The open side must face outward until the seal rests on the piston.
Install the brake fluid reservoir to the master cylinder. Refer to Brake Fluid Reservoir Removal and Installation .
Install the master cylinder assembly. Refer to Master Cylinder Assembly Removal and Installation .
Raise and suitably support the vehicle.
Bleed the braking system. Refer to Manual Bleeding the Brakes or BLEEDING SYSTEM. Bleed the clutch master cylinder. Refer to CLUTCH MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION .
Lower the vehicle.