Suzuki GSX-R 1000 Service Manual: 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 light switch (5) and brake lever
(6).

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

- Remove the following parts from the master cylinder.
- Piston (10)
- return spring (11)
- return spring guide (12)

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

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

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)

- When install the spring guide, insert the spring guide
end “a” into the hole “b” of the master cylinder

- Apply grease to the push rod.
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)

- Apply grease to the brake lever pivot bolt.
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)

- Tighten the pivot bolt (1) and lock-nut (2) to the
specified torque.
Tightening torque
brake lever pivot bolt (a): 1 n·m (0.1 Kgf-m, 0.5
Lbf-ft)
brake lever pivot bolt lock-nut (b): 6 n·m (0.6
Kgf-m, 4.5 Lbf-ft)

- When installing the brake light switch, align the
projection “c” on the switch with the hole “d” in the
master cylinder.

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 ...
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:
Exhaust control system operation
The excs is operated by the signal supplied from the ecm. The open/close
operation of the excv is performed by
the excva which is controlled by the ecm by changing the current direction of
the actuator motor. The position
sensor (incorporated in the excva) detects the excva movement by measuri ...
Procedure for returning
to service
Clean the entire motorcycle.
Remove the oily rags from the
air cleaner intake and muffler
outlet.
Drain all the engine oil. Install
a new oil filter and fill the
engine with fresh oil as outlined
in this manual.
Remove the spark plugs. Turn
the engine a few tim ...
Piston and piston ring inspection
Refer to “piston ring removal and installation” .
Piston diameter
Measure the piston diameter using the micrometer at 15
mm (0.6 In) “a” from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
Special tool
(a): 09900–20203 (micrometer (50 –
75 mm))
Pis ...