Suzuki Aerio, Verona 2002-06

Master Cylinder

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Overhaul




CAUTION
Never disassemble push rod assembly, disassembling will affect original performance of clutch system.

  1. Remove boot (1) and then circlip (2) with piston rod assembly (3) pushed in.

    Click image to see an enlarged view

    Fig. Remove master cylinder boot and circlip

  2.  
  3. Blow compressed air gradually into hole for pipe connection to remove piston assembly (1), using care to prevent it from jumping out.

    Click image to see an enlarged view

    Fig. Remove master cylinder piston assembly

  4.  

To install:


NOTE
Before installation, wash each part in specified brake fluid.

  1. Apply brake fluid to piston assembly and inside of cylinder body.
  2.  
  3. Install piston assembly into cylinder.
  4.  
  5. With piston and push rod assembly pushed down, install circlip.
  6.  
  7. Install boot.
  8.  

Removal & Installation




CAUTION
Do not allow fluid to get on painted surfaces.

  1. Clean around reservoir cap (7) and take out fluid with syringe or such.
  2.  
  3. Remove clevis b-pin (5) and clevis pin (4).
  4.  
  5. Disconnect fluid pipe (2) from master cylinder assembly (1) by loosing flare nut (6).
  6.  
  7. Remove master cylinder attaching nuts (3).
  8.  
  9. Remove master cylinder assembly (1) and gasket.

    Click image to see an enlarged view

    Fig. Removing master cylinder

  10.  

To install:

  1. To bleed air from master cylinder (1) itself, tilt it as shown and add fluid into it.
    NOTE
    After bleeding air from master cylinder, plug pipe hole in it to prevent fluid from spilling out of it till pipe is connected.



    Click image to see an enlarged view

    Fig. Tilting master cylinder

  2.  
  3. Install master cylinder assembly (1) and new gasket (2) to body, attaching nuts (3).
    NOTE
    Do not reuse gasket.

  4.  
  5. Tighten clutch master cylinder attaching nut to 9.5 ft. lbs. (13 Nm).
  6.  
  7. Connect fluid pipe and tighten flare nut (4) to 11.5 ft. lbs. (16 Nm).
  8.  
  9. Apply grease to clevis pin and install clevis pin.
  10.  
  11. Install clevis b-pin.

    Click image to see an enlarged view

    Fig. Installing master cylinder

  12.  
  13. Fill master cylinder reservoir with specified brake fluid and check fluid leakage.
  14.  
  15. After installation, bleed air from system.
  16.  
  17. Check clutch pedal free travel and clutch release margin.
  18.  

 
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