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Suzuki GSX-R 1000 Service Manual: Rear brake master cylinder assembly removal and installation

Suzuki GSX-R 1000 Service Manual / Brake / Brake control system and diagnosis / Repair instructions / Rear brake master cylinder assembly removal and installation

Refer to “rear brake hose routing diagram” (page 4a- 2).

Removal

  1. Remove the right side frame cover. Refer to “exterior parts removal and installation” in section 9d .
  2.  Remove the rear brake fluid reservoir mounting bolt (1).

Suzuki GSX-R. Rear brake master cylinder assembly removal and installation


  1. Drain brake fluid. Refer to “brake fluid replacement” .
  2.  Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.
  3.  Remove the brake hose union bolt (2).
  4.  Loosen the lock-nut (3).
  5.  Remove the master cylinder mounting bolts (4).
  6.  Remove the master cylinder along with the reservoir by turning the push rod (5).

Suzuki GSX-R. Rear brake master cylinder assembly removal and installation


Installation

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

Caution

the seal washers should be replaced with the new ones to prevent fluid leakage.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque rear brake master cylinder mounting bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft) brake hose union bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Rear brake master cylinder assembly removal and installation


Rear brake master cylinder components
Reservoir cap Plate Diaphragm Reservoir tank Reservoir hose Brake hose Brake hose union bolt Brake hose connector Master cylinder Spring Pis ...

Rear brake master cylinder disassembly and assembly
Refer to “rear brake master cylinder assembly removal and installation” . Disassembly Disconnect the reservoir hose (1).  Remove the lock-nut (2). Remove the brake hose connector ...

Other materials:

Fuel tank cap
To open the fuel tank cap, insert the ignition key into the lock and turn it clockwise. With the key inserted, lift up with the key and open the fuel tank cap. To close the fuel tank cap, push the cap down firmly with the key in the cap lock. Fuel level Fi ller neck Wa ...

Rear brake pedal removal and installation
Removal Remove the master cylinder assembly. Refer to “rear brake master cylinder assembly removal and installation” .  Disconnect the rear brake light switch lead wire coupler. Refer to “rear brake light switch inspection” .  Remove the rear brake pedal as shown in the rear ...

Oil pressure regulator / oil strainer inspection
Refer to “oil pan / oil pressure regulator / oil strainer removal and installation” . Oil pressure regulator Inspect the operation of the oil pressure regulator by pushing the piston with a proper bar. If the piston does not operate smoothly, replace the oil pressure regulator with a new on ...

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