Suzuki Burgman 400 - Service manual > Front Master Cylinder / Brake Lever Disassembly and Assembly

Refer to "Front Brake Master Cylinder Assembly Removal and Installation".

Disassembly

1) Remove the dust cover (1), brake lever (2) and brake light switch (3).

2) Remove the reservoir cap (4), plate (5) and diaphragm (6).

3) Pull out the dust boot (7) and remove the snap ring (8) using the special tool.

Special tool : 09900-06108 (Snap ring pliers)

4) Remove the following parts from the master cylinder.

• Piston/Cup set (9)
• Spring (10)

Assembly

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

! CAUTION

• 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.

BF: Brake fluid (DOT 4)

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

• Apply grease to the brake lever pivot bolt.
• Apply grease to the contact point between piston and brake lever.

: Grease 99000-25100 (SUZUKI Silicone Grease or equivalent)

Tightening torque
Brake lever pivot bolt: 1.0 N*m (0.1 kgf-m, 0.72 lb-ft)
Brake lever pivot bolt lock-nut: 6.0 N*m (0.6 kgf-m, 4.5 lb-ft)

Front Master Cylinder Parts Inspection

Refer to "Front Master Cylinder / Brake Lever Disassembly and Assembly".

Master Cylinder

Inspect the master cylinder bore for any scratches, corrosion or other damage. If any defects are found, replace it with the new ones.

Inner Parts

Inspect the piston/cup set, spring, snap ring and dust boot surface for any scratches or other damage. If any defects are found, replace it with the new ones.

Rear Brake Master Cylinder Components

1. Reservoir cap
2. Plate
3. Diaphragm
4. Master cylinder
5. Piston/Cup set
6. Brake hose union bolt
   1. : 10 N*m (1.0 kgf-m, 7.0 lb-ft)
   2. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)

: Apply brake fluid.

: Do not reuse.

See also: