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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
9900032110 (thread lock cement super 1322 or equivalent)

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

Throttle valve synchronization
Check and adjust the throttle valve synchronization among four cylinders.  Start the engine and run it in idling condition for warming up.  Stop the warmed-up engine.  Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page ...

Diagnostic information and procedures
Starting system symptom diagnosis Condition Possible cause Correction / reference item Engine does not turn though the starter motor runs Faulty starter clutch. Replace. Starter button is not effective Run down battery Repair or replac ...

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 ...

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