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:
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 ...