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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


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 m ...

Front brake master cylinder parts inspection
Refer to front brake master cylinder / brake lever disassembly and assembly . Master cylinder Inspect the master cylinder bore for any scratches or other damage Piston / rubber parts Insp ...

Other materials:

Specifications
Tightening torque specifications Note the specified tightening torque is described in the following. Rear view mirror construction Reference: for the tightening torque of fastener not specified in this section, refer to tightening torque list in section 0c . ...

Tire pressure and loading
Proper tire pressure and proper tire loading are important factors. Overloading your tires can lead to tire failure and loss of vehicle control. Check tire pressure each day before you ride, and be sure the pressure is correct for the vehicle load according to the table below. Tire pre ...

Front fork disassembly and assembly
Refer to front fork removal and installation (page 2b- 2). Note the right and left front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side. Disassembly Turn the spring pre-load adjuster (1) t ...

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