Suzuki AN400 - Front Brake Master Cylinder Assembly Removal and Installation

Brake Control System and Diagnosis: 4A-8
Front Brake Master Cylinder Assembly Removal
and Installation
B705H14106002
Removal
1) Remove the handlebar cover. Refer to “Handlebar
Cover Removal and Installation in Section 9D
(Page9D-13)”.
2) Remove the rear view mirror.
3) Drain the brake fluid. Refer to “Brake Fluid
Replacement (Page4A-5)”.
4) Disconnect the front brake light switch lead wire
couplers (1).
5) Place a rag underneath the union bolt (2) on the
master cylinder to catch any split brake fluid.
Remove the brake hose union bolt and disconnect
the brake hose.
6) Remove the master cylinder assembly.
Installation
Install the front brake master cylinder in the reverse
order of removal. Pay attention to the following points:
• When installing the master cylinder (1) onto the
handlebars (2), align the master cylinder holder’s
mating surface “A” with the punch mark “B” on the
handlebars (2) and tighten the upper holder bolt first
temporarily to provide clearance on the lower side and
then tighten both of the bolts to the specified torque.
Tightening torque
Master cylinder holder bolt (a): 10 N·m (1.0 kgf-
m, 7.0 lb-ft)
2
1
I705H1410005-01
I705H1410006-01
“C”: “Up” mark “a”: Clearance
(a)
1
2
“A”
“B”
I705H1410007-02
“a”
1
2
(a)
“A”
“B”
“C”
I705H1410018-02