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Suzuki GSX-R 1000 Service Manual: Front brake master cylinder / brake lever disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Brake / Brake control system and diagnosis / Repair instructions / 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).

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


  1. Remove the following parts from the master cylinder.

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


: Grease 9900025100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


: Grease 9900025100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Tightening torque brake lever pivot bolt (a): 1 nm (0.1 Kgf-m, 0.5 Lbf-ft) brake lever pivot bolt lock-nut (b): 6 nm (0.6 Kgf-m, 4.5 Lbf-ft)

Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


Suzuki GSX-R. Front brake master cylinder / brake lever disassembly and assembly


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 m ...

Front brake master cylinder parts inspection
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:

Brake pad
Front Rear Inspect the front and rear brake pads to see if they are worn down to the grooved wear limit line 1. If a pad is worn to the grooved wear limit line, it must be replaced with a new one. After replacing either the front or rear brake pads, the brake lever or pedal must be ...

DTC c40 (p0505 / p0506 / p0507): isc valve circuit malfunction
Detected condition and possible cause Detected condition Possible cause C40/P0505 The circuit voltage of motor drive is unusual. Isc valve circuit open or shorted to ground. Air passage clogged.  Isc valve is fixed.  Isc valve prese ...

Clutch removal
Drain engine oil. Refer to engine oil and filter replacement in section 0b .  Lift and support the fuel tank with the prop stay. Refer to fuel tank removal and installation in section 1g .  Disconnect the ckp sensor coupler (1). Remove the clutch cover (2). ...

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