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.
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:
Brake fluid replacement
Caution
handle brake fluid with care: the fluid reacts
chemically with paint, plastic, rubber
materials, etc.
Front brake
Place the motorcycle on a level surface and keep the
handlebars straight.
Remove the brake fluid reservoir cap and
diaphragm.
Suck u ...
DTC “c49” (p1656): pair control solenoid
valve circuit malfunction
Detected condition and possible cause
Detected condition
Possible cause
Pair control solenoid valve voltage is not input to ecm
Pair control solenoid valve circuit open or short.
Pair control solenoid valve malfunction.
Ecm malfunction.
...
Inspection before riding
Warning
Failure to inspect and maintain
your motorcycle properly
increases the chance of an
accident or equipment damage.
Always perform a pre-ride
inspection before each ride.
Refer to the table on page 4-4
for check items. For further
details, refer to the inspec· ...