Front brake master cylinder / brake lever disassembly and assembly

Refer to “front brake master cylinder assembly removal and installation” .

1. Remove the reservoir cap (1), plate (2), diaphragm (3) and reservoir tank (4).

2. Remove the brake light switch (5) and brake lever (6).

1. 1
   Remove the dust boot (7) and push rod (8).
2. 2
   Remove the snap ring (9).

   

5. Remove the following parts from the master cylinder.

• Piston (10)
• return spring (11)
• return spring guide (12)

6. Remove the dust rubber (13) and snap ring (14).

7. Remove the connector (15), o-ring (16) and air bleeder valve (17).

Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

• wash the master cylinder components with new brake fluid before reassembly.
• Do not wipe the brake fluid off after washing the components.
• When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
• Apply brake fluid to the master cylinder bore and all of the master cylinder component to be inserted into the bore.

• When install the spring guide, insert the spring guide end “a” into the hole “b” of the master cylinder

• Apply grease to the push rod.

: Grease 99000–25100 (suzuki
silicone grease or equivalent)

• Apply grease to the brake lever pivot bolt.

: Grease 99000–25100 (suzuki
silicone grease or equivalent)

• Tighten the pivot bolt (1) and lock-nut (2) to the specified torque.

• When installing the brake light switch, align the projection “c” on the switch with the hole “d” in the master cylinder.