Suzuki GSX-R 1000 Service Manual: Rear brake master cylinder assembly removal and installation
Refer to “rear brake hose routing diagram” (page 4a-
2).
Removal
- Remove the right side frame cover. Refer to “exterior parts removal and
installation” in section 9d .
- Remove the rear brake fluid reservoir mounting bolt
(1).

- Drain brake fluid. Refer to “brake fluid replacement” .
- 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).
- Loosen the lock-nut (3).
- Remove the master cylinder mounting bolts (4).
- Remove the master cylinder along with the reservoir
by turning the push rod (5).

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. |
- Apply thread lock to the master cylinder mounting
bolts (1) and tighten them to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
- Tighten the lock-nut (2) temporarily.
- After setting the brake hose union to the stopper,
tighten the union bolt (3) to the specified torque.
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)

- Bleed air from the brake system after reassembling the master cylinder.
Refer to “air bleeding from brake fluid circuit” .
- Adjust the brake pedal height. Refer to “brake pedal height inspection
and adjustment” .
- Install the removed parts.
Reservoir cap
Plate
Diaphragm
Reservoir tank
Reservoir hose
Brake hose
Brake hose union bolt
Brake hose connector
Master cylinder
Spring
Pis ...
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:
DTC table
In the lcd (display) panel, the malfunction code is indicated from small code
to large code.
*1 To get the proper signal from the throttle position sensor, the sensor basic
position is indicated in the lcd
(display) panel. The malfunction code is indicated in three digits. In front o ...
Malfunction code and defective condition table
* : Immobilizer system equipped model only. ...
Drive chain cleaning and lubricating
Clean and lubricate drive chain
every 1 000 km (600 miles)
Clean and lubricate the drive chain in the following
procedures:
clean the drive chain with kerosine. If the drive chain
tends to rust quickly, the intervals must be
shortened.
Caution
do not use trichloroethyle ...