Suzuki RM 250 2003 - Rear Master Cylinder Reassembly; Brake Pedal; Removal; Reassembly

14-14 FRONT AND REAR BRAKES
REAR MASTER CYLINDER REASSEMBLY
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
• Tighten the master cylinder mounting bolts
1 to the specified
torque.
# Master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Tighten the brake hose union bolt
2 to the specified torque.
# Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Refill brake fluid and bleed air from the brake system.
($14-4)
BRAKE PEDAL
REMOVAL
• Remove the cotter pin
1 and brake pedal pivot bolt.
• Remove the return spring.
• Remove the cotter pin
2, washer and pin.
REASSEMBLY
• Fit the return spring properly.
• Apply SUZUKI SUPER GREASE to the brake pedal pivot bolt.
( 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Tighten the brake pedal pivot bolt to the specified torque.
# Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)
• Install new cotter pins.
• Adjust the brake pedal height. ($2-20)
CAUTION
Improper brake hose routing can damage the brake
hose.
Set the brake hose so it touches the stopper and
tighten the union bolt. Ensure the brake hose has
enough clearance to the rear suspension spring.