Suzuki GSX-R 1000 Service Manual: 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 light switch (5) and brake lever
(6).

- Remove the dust boot (7) and push rod (8).
- Remove the snap ring (9).

- Remove the following parts from the master cylinder.
- Piston (10)
- return spring (11)
- return spring guide (12)

- Remove the dust rubber (13) and snap ring (14).

- Remove the connector (15), o-ring (16) and air
bleeder valve (17).

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)

- When install the spring guide, insert the spring guide
end “a” into the hole “b” of the master cylinder

- Apply grease to the push rod.
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)

- Apply grease to the brake lever pivot bolt.
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)

- Tighten the pivot bolt (1) and lock-nut (2) to the
specified torque.
Tightening torque
brake lever pivot bolt (a): 1 n·m (0.1 Kgf-m, 0.5
Lbf-ft)
brake lever pivot bolt lock-nut (b): 6 n·m (0.6
Kgf-m, 4.5 Lbf-ft)

- When installing the brake light switch, align the
projection “c” on the switch with the hole “d” in the
master cylinder.

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 m ...
Refer to “front brake master cylinder / brake lever disassembly and assembly”
.
Master cylinder
Inspect the master cylinder bore for any scratches or
other damage
Piston / rubber parts
Insp ...
Other materials:
Swingarm bearing removal and installation
Removal
Remove the swingarm. Refer to “swingarm removal and installation” .
Remove the swingarm pivot bearings (1) using the
special tool.
Special tool
(a):
09921–20240 (bearing remover set)
Remove the center spacer (2).
Remove the cushion lever bearing (3) usin ...
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Lubrication points”
Special tool
...
Emission control warranty
Suzuki motor corporation warrants
to the ultimate purchaser
and each subsequent purchaser
that this vehicle is designed, built,
and equipped so as to conform at
the time of sale with all U.S. Emission
standards applicable at the
time of manufacture, and that it is
free from defects in materi ...