Suzuki GSX-R 1000 Service Manual: Rear brake master cylinder disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Brake / Brake control system and diagnosis / Repair instructions / 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).

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Remove the brake hose connector (3) and o-ring (4).

Special tool : 09900–06108 (snap ring remover
(close type))

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Pull out the dust boot (5) and remove the snap ring (6).

Special tool : 09900–06108 (snap ring remover
(close type))

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Remove the push rod (7), piston/cup set (8) and spring (9).

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Assembly

Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

Caution

wash the master cylinder components with new brake fluid before reassembly.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Apply brake fluid to the master cylinder bore and all of the master cylinder component to be inserted into the bore.

Bf: brake fluid (dot 4)

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Apply grease to the push rod end.

: Grease 99000–25100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

Caution

replace the o-ring with a new one.

Suzuki GSX-R. Rear brake master cylinder disassembly and assembly

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 ...

Rear brake master cylinder parts inspection

Refer to “rear brake master cylinder disassembly and assembly” . Master cylinder Inspect the master cylinder bore for any scratches or other damage. Piston / rubber parts Inspect the piston s ...

Other materials:

Cam chain guide inspection
Inspect the cam chain guide in the following procedures: remove the cam chain guides. Refer to “cam chain guide / cam chain tensioner removal and installation” . Check the contacting surface of the cam chain guides. If it is worn or damaged, replace it with a new one. ...

Gearshift linkage inspection
Refer to “gearshift shaft / gearshift cam plate removal and installation” . Gearshift shaft Check the gearshift shaft for bend or wear. Check the return spring for damage or fatigue. If any defects are found, replace the defective part(-s). Gearshift shaft oil seal Inspect the gearshif ...

Special tools and equipment
Recommended service material Note required service material is also described in the following. “Water hose routing diagram” “water pump components” “water pump construction” Special tool ...