Master Cylinder Reassembly And Remounting - Suzuki DL650K5 Service Manual

MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
#
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning
solvent or gasoline to wash them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the
component to be inserted into the bore.
, Specification and Classification: DOT 4
• Apply brake fluid to the piston and cups.
• Install the following parts to the master cylinder.
1 Dust boot
2 Snap ring
3 Secondary cup
4 Piston
5 Primary cup
6 Return spring
• When remounting the brake master cylinder 7 onto the han-
dlebars, align the master cylinder holder's mating surface A
with punch mark B on the handlebars 8 as shown.
• Tighten the front brake master cylinder mounting bolt to the
specified torque and first tighten the upper mounting bolt.
! Front brake master cylinder mounting bolt:
• Tighten the union bolt to the specified torque. (Brake hose
routing: "9-26)
! Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
#
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the
master cylinder. ("2-25)
10 N·m (1.0 kgf-m, 7.0 lb-ft)
9 Master cylinder holder
C "UP" mark
CHASSIS 7-67