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

Suzuki GSX-R 1000 Service Manual / Brake / Brake control system and diagnosis / Repair instructions / 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).

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Remove the brake hose connector (3) and o-ring (4).

Special tool : 09900–06108 (snap ring remover
(close type))

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Pull out the dust boot (5) and remove the snap ring (6).

Special tool : 09900–06108 (snap ring remover
(close type))

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Remove the push rod (7), piston/cup set (8) and spring (9).

Suzuki GSX-R. Rear brake master cylinder 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. Rear brake master cylinder disassembly and assembly

Apply grease to the push rod end.

: Grease 99000–25100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Caution

replace the o-ring with a new one.

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Rear brake master cylinder assembly removal and installation

Refer to “rear brake hose routing diagram” (page 4a- 2). Removal Remove the right side frame cover. Refer to “exterior parts removal and installation” in section 9d . Remove the rear ...

Rear brake master cylinder parts inspection

Refer to “rear brake master cylinder disassembly and assembly” . Master cylinder Inspect the master cylinder bore for any scratches or other damage. Piston / rubber parts Inspect the piston s ...

Other materials:

Tightening torque list
Engine Fi system + intake air system Cooling system Chassis Tightening torque chart For other bolts and nuts not listed in the preceding page, refer to this chart: Conventional bolt “4” Marked bolt “7” Marked bolt ...

Ignition coil and spark plug removal and installation
Removal The hot engine can burn you. Wait until the engine is cool enough to touch. Turn the ignition switch off. Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d . Disconnect the lead wire couplers (1). ...

Specifications
Service data Fi sensors Tightening torque specifications Note the specified tightening torque is described in the following. “Exhaust control system construction” “exhaust system components” Reference: for the tightening torque of fastener not specified in this ...