Master Cylinder Assembly Disassembly And Assembly - Suzuki Swift Sport 2004 Service & Repair Manual

4A-14 Brake Control System and Diagnosis:
6) Fill reservoir with specified fluid.
7) After completing the work, bleed air from brake and
clutch system referring to "Air Bleeding of Brake
System" and "Air Bleeding of Clutch System in
Section 5C" (M/T model).
8) Install cowl top panel referring to "Cowl Top
Components in Section 9K".
9) Install windshield wiper referring to "Windshield
Wiper Removal and Installation in Section 9D".
10) Perform brake test and check each installed part for
fluid leakage.
Master Cylinder Assembly Disassembly and
Assembly
Disassembly
1) Push in primary piston (1) to remove secondary
piston stopper pin (2) from master cylinder as
shown.
2) Remove circlip (1).
3) Remove piston guide and primary piston. Then
remove secondary piston by blowing compressed air
(2) into hole. Be cautions during removal as
secondary piston jumps out.
WARNING
!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth to prevent piston from
damage. It should be taken out gradually with
moderately compressed air. Do not place
your fingers in front of piston when using
compressed air.
Assembly
CAUTION
!
• Never use any mineral oil such as
kerosene oil and gasoline when washing
and assembling parts.
• Check inside of cylinder wall, pistons and
cup seals are free from any foreign objects
such as dust and dirt and use case not to
cause any damage with a tool during
assembly.
• Do not drop parts. Do not use any part
which has been dropped.
1) Apply brake fluid to inside of cylinder and contact
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surface of piston assembly (new piston cups, new O-
ring and piston guide).
2) Install secondary return spring and secondary piston
(1) into cylinder body (4).
NOTE
Align oblong hole in secondary piston (2)
with stopper pin hole (3) in master cylinder
body (4) when installing it.
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3) Install primary piston assembly into cylinder body.
4) Install piston stopper pin (2) with pistons pushed in
all the way and install it.
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