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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:

Rod guide case tightening torque
Tighten the rod guide case in the following procedures: measure the effective length l of the torque wrench. Calculate the reading torque on the torque wrench by use of the formula shown below. Special tool (a): 0994084710 (rod guide case wrench) T: reading torque on the torq ...

Oil pressure regulator / oil strainer inspection
Refer to oil pan / oil pressure regulator / oil strainer removal and installation . Oil pressure regulator Inspect the operation of the oil pressure regulator by pushing the piston with a proper bar. If the piston does not operate smoothly, replace the oil pressure regulator with a new on ...

Air cleaner element inspection
Inspect air cleaner element every 6 000 km (4 000 miles, 12 months) Inspection Remove the air cleaner element. Refer to air cleaner element removal and installation in section 1d .  Inspect the air cleaner element for clogging. If it is clogged with dirt, replace it with a new on ...

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