Toyota RAV4 manuals

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:

Battery removal and installation
Removal Remove the front seat. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Disconnect the battery () lead wire (1).  Disconnect the battery (+) lead wire (2). Note be sure to disconnect the battery () lead wire (1) first, th ...

Noise emission control system description
Tampering with the noise control system prohibited: local law or federal law prohibits the following acts or the causing thereof:  the removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design in ...

Special tools and equipment
Recommended service material Note required service material is also described in the following. Exhaust system components Special tool ...

2011-2019 Copyright www.suzukigsxr.org