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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

  1. Disconnect the reservoir hose (1).
  2.  Remove the lock-nut (2).

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


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

Special tool : 0990006108 (snap ring remover
(close type))

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


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

Special tool : 0990006108 (snap ring remover
(close type))

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


  1. 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


: Grease 9900025100 (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:

Engine top side assembly
Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Cylinder head Install the dowel pins and a new cylinder head gasket (1) to the cylinder. Caution use a new gasket to prevent gas leakage. Place the cylinder head ...

Starter motor inspection
Refer to starter motor disassembly and assembly . Carbon brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one. Measure the length a of the carbon brushes using a v ...

Engine stop switch inspection
Inspect the engine stop switch in the following procedures:  turn the ignition switch off.  Remove the air cleaner box. Refer to air cleaner box removal and installation in section 1d .  Disconnect the right handlebar switch coupler (1). Inspect the engine stop ...

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