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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:

Steering system inspection
Inspect steering system initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtighten steering prevents smooth turning of the handlebars and too loose steer ...

Turn signal switch inspection
Inspect the turn signal switch in the following procedures:  remove the air cleaner box. Refer to air cleaner box removal and installation in section 1d .  Disconnect the left handlebar switch coupler (1). (Yellow) Inspect the turn signal switch for continuity wit ...

Short circuit check (wire harness to ground)
Disconnect the negative () cable from the battery.  Disconnect the connectors/couplers at both ends of the circuit to be checked. Note if the circuit to be checked branches to other parts as shown, disconnect all connectors/ couplers of those parts. Otherwise, diagnos ...

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