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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
Service data Injector + fuel pump + fuel pressure regulator Fuel Tightening torque specifications Note the specified tightening torque is described in the following. Fuel pump components Reference: for the tightening torque of fastener not specified in this se ...

Pair system hose routing diagram
Pair control solenoid valve Pair reed valve White marking (hidden side) Yellow marking Blue marking Red marking Face the clamp end to the top. Make sure the clamp is not contacted to the frame or air cleaner box. 90 45 15 ...

Isc valve preset and opening initialization
When removing or replacing the isc valve, set the isc valve to the following procedures:  turn the ignition switch on.  Set up the sds tool. (Refer to the sds operation manual for further details.)  Click the active control.  Click the isc learned value reset (1) ...

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