Suzuki GSX-R 1000 Service Manual: 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).

5. Remove the master cylinder assembly.

Installation

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

•  when installing the master cylinder (1) onto the handlebar, align the master cylinder holder’s mating surface “a” with the punch mark “b” on the handlebar and tighten the upper holder bolt first.

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

• After setting the brake hose union to the stopper, tighten the union bolt (2) to the specified torque.

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

• Bleed air from the master cylinder in the same manner as caliper side.

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

• Bleed air from brake system. Refer to “air bleeding from brake fluid circuit” .