Master Cylinder Reassembly And Remounting - Suzuki DL650 Service Manual

CHASSI S 7-67
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.
a
Specification and Classification: DOT 4
Apply brake fluid to the piston and cups.
Install the following parts to the master cylinder.
@
Dust boot
@
Snap ring
O
Secondary cup
@
Piston
@
Primary cup
@
Return spring
When remounting the brake master cylinder
O
onto the han-
dlebars, align the master cylinder holder's mating surface
@
with punch mark
@
on the handlebars
@
as shown.
Tighten the front brake master cylinder mounting bolt to the
specified torque and first tighten the upper mounting bolt.
rn
Front brake master cylinder mounting bolt:
10 N-m (1.0 kgf-m, 7.0 Ib-ft)
@
Master cylinder holder
@
" U P mark
Tighten the union bolt to the specified torque. (Brake hose
routing:
-9-26)
rn
Brake hose union bolt:
23
N-m
(2.3
kgf-m, 16.5 Ib-ft)
The seal washers should be replaced with the new
ones to prevent fluid leakage.