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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:

Corrosion prevention
It is important to take good care of your motorcycle to protect it from corrosion and keep it looking new for years to come. Important information about corrosion Common causes of corrosion Accumulation of road salt, dirt, moisture, or chemicals in hardto- reach areas.  Chipping ...

Radiator cap inspection
Inspect the radiator cap in the following procedures:  remove the radiator cap. Refer to cooling circuit inspection .  Attach the radiator cap (1) to the radiator tester (2) as shown. Slowly apply pressure to the radiator cap. If the radiator cap does not hold the pre ...

Clutch control system components
Push rod Clutch release camshaft Clutch release arm Clutch cable 1 Nm (0.1 Kgf-m, 0.7 Lbf-ft) 6 Nm (0.6 Kgf-m, 4.5 Lbf-ft) 10 Nm (1.0 Kgf-m, 0.7 Lbf-ft) Apply grease Do not reuse. ...

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