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Suzuki GSX-R 1000 Service Manual: Front brake master cylinder / brake lever disassembly and assembly

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

Refer to front brake master cylinder assembly removal and installation .

Disassembly

  1. Remove the reservoir cap (1), plate (2), diaphragm (3) and reservoir tank (4).

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


  1. Remove the brake light switch (5) and brake lever (6).

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


  1. Remove the dust boot (7) and push rod (8).
  2.  Remove the snap ring (9).

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


  1. Remove the following parts from the master cylinder.

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


  1. Remove the dust rubber (13) and snap ring (14).

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


  1. Remove the connector (15), o-ring (16) and air bleeder valve (17).

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Assembly

Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

Caution

  •  wash the master cylinder components with new brake fluid before reassembly.
  •  Do not wipe the brake fluid off after washing the components.
  •  When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
  •  Apply brake fluid to the master cylinder bore and all of the master cylinder component to be inserted into the bore.

Bf: brake fluid (dot 4)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


: Grease 9900025100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


: Grease 9900025100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Tightening torque brake lever pivot bolt (a): 1 nm (0.1 Kgf-m, 0.5 Lbf-ft) brake lever pivot bolt lock-nut (b): 6 nm (0.6 Kgf-m, 4.5 Lbf-ft)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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