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Suzuki GSX-R 1000 Service Manual: Front brake master cylinder assembly removal and installation

Suzuki GSX-R 1000 Service Manual / Brake / Brake control system and diagnosis / Repair instructions / Front brake master cylinder assembly removal and installation

Removal

  1. Drain brake fluid. Refer to brake fluid replacement .
  2.  Disconnect the front brake light switch coupler (1).
  3.  Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
  4.  Remove the brake hose union bolt (2).

Suzuki GSX-R. Front brake master cylinder assembly removal and installation


  1. Remove the master cylinder assembly.

Suzuki GSX-R. Front brake master cylinder assembly removal and installation


Installation

Install the front brake master cylinder in the reverse order of removal. Pay attention to the following points:

Tightening torque front brake master cylinder holder bolt (upper and lower) (a): 10 nm (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Front brake master cylinder assembly removal and installation


Suzuki GSX-R. Front brake master cylinder assembly removal and installation


  1. Up mark
  2. Clearance
Caution

the seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque brake hose union bolt (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front brake master cylinder assembly removal and installation


Note

if air is trapped in the master cylinder, bleed air from the master cylinder first.

Tightening torque air bleeder valve (front master cylinder): 6 nm ( 0.6 Kgf-m, 4.5 Lbf-ft)

Suzuki GSX-R. Front brake master cylinder assembly removal and installation


Front brake master cylinder components
Reservoir cap Plate Diaphragm Reservoir tank Master cylinder Dust boot Piston set Brake lever Brake lever pivot bolt Brake lever pivot bolt lock ...

Front brake master cylinder / brake lever disassembly and assembly
Refer to front brake master cylinder assembly removal and installation . Disassembly Remove the reservoir cap (1), plate (2), diaphragm (3) and reservoir tank (4). Remove the brake ...

Other materials:

Oil jet inspection
Refer to oil jet removal and installation . Oil jet Make sure that the oil jets are not clogged. If they are clogged, clean their oil passage using a wire of the proper size and compressed air. Piston cooling jet Oil jet (for transmission) Oil jet (for cam chain te ...

Wiring diagram
Refer to wire color symbols in section 0a . For e-02, 19, 24, 51 For e-03, 28 For e-14, 33 ...

Conrod crank pin bearing inspection and selection
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. Place the plastigauge axially along ...

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