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

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

Removal

  1. Drain brake fluid. Refer to brake fluid replacement .
  2.  Disconnect the front brake light switch coupler (1).
  3.  Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
  4.  Remove the brake hose union bolt (2).

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


  1. Remove the master cylinder assembly.

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


Installation

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

Tightening torque front brake master cylinder holder bolt (upper and lower) (a): 10 nm (1.0 Kgf-m, 7.0 Lbf-ft)

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


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


  1. Up mark
  2. Clearance
Caution

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

Tightening torque brake hose union bolt (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

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


Note

if air is trapped in the master cylinder, bleed air from the master cylinder first.

Tightening torque air bleeder valve (front master cylinder): 6 nm ( 0.6 Kgf-m, 4.5 Lbf-ft)

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


Front brake master cylinder components
Reservoir cap Plate Diaphragm Reservoir tank Master cylinder Dust boot Piston set Brake lever Brake lever pivot bolt Brake lever pivot bolt lock ...

Front brake master cylinder / brake lever disassembly and assembly
Refer to front brake master cylinder assembly removal and installation . Disassembly Remove the reservoir cap (1), plate (2), diaphragm (3) and reservoir tank (4). Remove the brake ...

Other materials:

Right handlebar
Engine stop switch 1 "" Position The ignition circuit is off. The engine cannot start or run. "" Position The ignition circuit is on and the engine can run. Front brake lever 2 Apply the front brake by squeezing the front brake lever towards the grip. The brake ligh ...

Water hose inspection
Inspect the water hoses in the following procedures:  remove the side cowlings. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Check the water hoses for crack, damage or engine coolant leakage. If any defect is found, replace the water hose wi ...

Side standngnition interlock switch
Check the side stand/ignition interlock system for proper operation as follows:  Sit on the motorcycle in the normal riding position, with the side stand up.  Shift into first gear, hold the clutch in, and start the engine.  While continuing to hold the clutch in ...

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