Suzuki GSX-R 1000 Service Manual: Front brake master cylinder assembly removal and installation
Removal
- Drain brake fluid. Refer to “brake fluid replacement” .
- Disconnect the front brake light switch coupler (1).
- Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
- Remove the brake hose union bolt (2).
- 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.
| Caution the seal washers should be replaced with the new ones to prevent fluid leakage. |
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.
| 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 n·m ( 0.6 Kgf-m, 4.5 Lbf-ft)
- Bleed air from brake system. Refer to “air bleeding from brake fluid circuit” .
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:
Evaporative emission control system
diagram (only for e-33)
Fuel tank
Fuel-vapor separator
Fuel pump
Fuel feed hose
Fuel shut-off valve
Iap sensor
Surge hose
Evap canister
Purge hose
Evap system purge control solenoid valve
Fue
Hc vapor
Fresh air
Vacuum
...
License plate light bulb replacement
Caution
when you touch the bulb with your bare
hands, clean the bulb with a cloth moistened
with alcohol or soap water to prevent
premature bulb failure.
Remove the license plate light mounting nuts.
Remove the lens cover (1) by removing the screws.
Re ...
Cam chain guide / cam chain tensioner
removal and installation
Removal
Remove the cylinder head cover. Refer to “engine top side disassembly” .
Remove the cam chain guide no. 2 (1).
Remove the cylinder head. Refer to “engine top side disassembly”
and “engine bottom side disassembly” .
Remove the starter clutch. Refer to “s ...