General Description; Master Cylinder Assembly; Booster Assembly - Suzuki sq-416-420-625 Service Manual

5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER

MASTER CYLINDER ASSEMBLY

The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary ("a"
in the figure below) and secondary ("b") chambers. The hydraulic pressure produced in the primary chamber ("a")
acts on the front (for vehicle without ABS, rear) wheel brakes.
Also, the hydraulic pressure produced in the secondary chamber ("b") acts on the rear (for vehicle without ABS,
front) wheel brakes.
NOTE:
Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with
clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rub-
ber components may result. If any hydraulic component is removed or brake line disconnected, bleed the
brake system.
The torque values specified are for dry, unlubricated fasteners.
[A]
[B]

BOOSTER ASSEMBLY

The booster is located between the master cylinder and the brake pedal. It is so designed that the force created
when the brake pedal is depressed is mechanically increased combined with the engine vacuum.
The booster has two diaphragms of
CAUTION:
D Never disassemble brake booster assembly. If it is found faulty, replace it with new assembly.
D The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is re-
moved or brake line disconnected, bleed the brake system.

GENERAL DESCRIPTION

ø
7.5 in. (191 mm) effective diameter.
[A]: With ABS
[B]: Without ABS
1. Piston stopper circlip
2. Piston stopper
3. Cylinder cup
4. Plate
5. Primary piston
6. Piston cup
7. Primary piston return spring
8. Primary spring retainer
9. Secondary piston pressure cup
10. Secondary piston
11. Return spring secondary seat
12. Secondary piston return spring
13. Secondary piston stopper bolt
14. Master cylinder body
"A": Primary piston
"B": Secondary piston