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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

  1. Disconnect the reservoir hose (1).
  2.  Remove the lock-nut (2).

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


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

Special tool : 0990006108 (snap ring remover
(close type))

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


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

Special tool : 0990006108 (snap ring remover
(close type))

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


  1. 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


: Grease 9900025100 (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:

Special tools and equipment
Special tool ...

Engine coolant
Coolant level The engine coolant solution should be between "f" (full) and "1..:' (Low) level lines on the engine coolant reservoir. If the level is lower than "1..:' (Low) level line, bring it up to "f" (full) level by adding 50:50 mixture of distilled water ...

DTC c12 (p0335): ckp sensor circuit malfunction.
Detected condition and possible cause Detected condition Possible cause The signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Metal particles or foreign material being stuck on the ckp sensor and rotor tip.  Ckp ...

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