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

1. Remove the reservoir cap (1), plate (2), diaphragm (3) and reservoir tank (4).

2. Remove the brake light switch (5) and brake lever (6).

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

5. Remove the following parts from the master cylinder.

•  Piston (10)
•  return spring (11)
•  return spring guide (12)

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

7. 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:

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.