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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:

Front brake pad inspection
The extent of brake pads wear can be checked by observing the grooved limit line a on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to front brake pad replacement . Caution replace the brake pad as a set, otherwise braking perform ...

Brake fluid replacement
Caution handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc. Front brake Place the motorcycle on a level surface and keep the handlebars straight.  Remove the brake fluid reservoir cap and diaphragm.  Suck u ...

Warning / caution / note
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could ...

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