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Suzuki GSX-R 1000 Service Manual: Rear brake master cylinder assembly removal and installation

Suzuki GSX-R 1000 Service Manual / Brake / Brake control system and diagnosis / Repair instructions / Rear brake master cylinder assembly removal and installation

Refer to rear brake hose routing diagram (page 4a- 2).

Removal

  1. Remove the right side frame cover. Refer to exterior parts removal and installation in section 9d .
  2.  Remove the rear brake fluid reservoir mounting bolt (1).

Suzuki GSX-R. Rear brake master cylinder assembly removal and installation


  1. Drain brake fluid. Refer to brake fluid replacement .
  2.  Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
  3.  Remove the brake hose union bolt (2).
  4.  Loosen the lock-nut (3).
  5.  Remove the master cylinder mounting bolts (4).
  6.  Remove the master cylinder along with the reservoir by turning the push rod (5).

Suzuki GSX-R. Rear brake master cylinder assembly removal and installation


Installation

Install the rear brake master cylinder in the reverse order of removal. Pay attention to the following points:

Caution

the seal washers should be replaced with the new ones to prevent fluid leakage.

: Thread lock cement
9900032110 (thread lock cement super 1322 or equivalent)

Tightening torque rear brake master cylinder mounting bolt (a): 10 nm (1.0 Kgf-m, 7.0 Lbf-ft) brake hose union bolt (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Rear brake master cylinder assembly removal and installation


Rear brake master cylinder components
Reservoir cap Plate Diaphragm Reservoir tank Reservoir hose Brake hose Brake hose union bolt Brake hose connector Master cylinder Spring Pis ...

Rear brake master cylinder disassembly and assembly
Refer to rear brake master cylinder assembly removal and installation . Disassembly Disconnect the reservoir hose (1).  Remove the lock-nut (2). Remove the brake hose connector ...

Other materials:

Precautions
Precautions for engine cooling system You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pr ...

DTC c93 (p1769): steering damper solenoid valve circuit malfunction
Detected condition and possible cause Detected condition Possible cause C93 Steering damper control current does not flow to the solenoid valve. With ig turned on, ecm detects a failure of internal circuit element. Solenoid current does not converge to the ...

Front wheel components
Front axle Brake disc bolt Brake disc Dust seal Bearing Spacer Air valve Front wheel Wheel balancer Front tire Collar Front axle bolt 18 Nm (1.8 Kgf-m, 13.0 Lbf-ft) 100 Nm (10.0 Kgf-m, 72.5 Lbf-ft) Apply ...

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