Rear Disc Brake Caliper Disassembly and Reassembly: Reassembly

CAUTION:

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

Before install piston to brake caliper, check piston and caliper as below.

Check all around piston for rust, corrosion and any other damage. If it is found faulty, replace piston or brake caliper.

Fig 1: Identifying Piston
Courtesy of SUZUKI OF AMERICA CORP.
Push in adjusting bolt (1) by hand and move lever to check that adjusting bolt (1) moves smoothly in the arrow direction.
Also, check adjusting bolt (1) for any damage. If it is found faulty, replace brake caliper.

Fig 2: Locating Adjusting Bolt Position
Courtesy of SUZUKI OF AMERICA CORP.

Apply thread lock cement to shaft thread (6) of caliper.
"A": Thread lock cement 99000-32110 (Thread Lock Cement Super 1322)
Apply grease to inside of new shaft cover (1).
Install new shaft cover, lever (2), washer (3), parking nut (4) and return spring (5) to caliper.
Tightening torque

Parking nut (a): 27 N.m (2.7 kg-m, 19.5 lbf-ft)

Fig 3: Installing New Shaft Cover, Lever, Washer, Parking Nut And Return Spring To Caliper
Courtesy of SUZUKI OF AMERICA CORP.
Install bleeder plug and cap to caliper.
Install new piston seal to caliper.
Before inserting piston (2) into cylinder, install boot (1) onto piston as shown.

Fig 4: Installing Boot Onto Piston
Courtesy of SUZUKI OF AMERICA CORP.
Fit boot as it is in figure into boot groove in cylinder with fingers.

Fig 5: Fitting Boot Into Boot Groove In Cylinder
Courtesy of SUZUKI OF AMERICA CORP.
Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
NOTE: Check that boot is fitted in boot groove securely all around piston.

Special Tool

(A): 09945-16060

Fig 6: Turning Brake Caliper Piston
Courtesy of SUZUKI OF AMERICA CORP.