Suzuki GSX-R 1000 Service Manual: Front brake master cylinder assembly removal and installation
Removal
- Drain brake fluid. Refer to “brake fluid replacement” .
- Disconnect the front brake light switch coupler (1).
- Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
- Remove the brake hose union bolt (2).
- Remove the master cylinder assembly.
Installation
Install the front brake master cylinder in the reverse order of removal. Pay attention to the following points:
- when installing the master cylinder (1) onto the handlebar, align the master cylinder holder’s mating surface “a” with the punch mark “b” on the handlebar and tighten the upper holder bolt first.
Tightening torque front brake master cylinder holder bolt (upper and lower) (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)
|
- After setting the brake hose union to the stopper, tighten the union bolt (2) to the specified torque.
| Caution the seal washers should be replaced with the new ones to prevent fluid leakage. |
Tightening torque brake hose union bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)
- Bleed air from the master cylinder in the same manner as caliper side.
| 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 n·m ( 0.6 Kgf-m, 4.5 Lbf-ft)
- Bleed air from brake system. Refer to “air bleeding from brake fluid circuit” .
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:
Engine oil and filter change
Change the engine oil and oil filter
at the scheduled times. The
engine should always be warm
when the oil is changed so the oil
will drain easily. The procedure is
as follows:
Place the motorcycle on the
side stand.
Remove the three screws of
the right fairing 1.
...
Spark plugs
Your motorcycle comes equipped
with ngk cr9e or denso
u27esr-n spark plugs. To determine
if the standard spark plug is
right for your usage, check the
color of the plug's porcelain center
electrode insulator after motorcycle
operation. A light brown
color indicates that the plug is correct.
...
Camshaft inspection
Refer to “engine top side disassembly” .
Refer to “engine top side assembly” .
Camshaft identification
The exhaust camshaft has the embossed letters “ex”
and the intake camshaft has the embossed letters “in”.
Cam wear
Check the camshaft for wear or damage.
Measure the cam height “a” w ...