Suzuki GSX-R 1000 Service Manual: Front brake master cylinder / brake lever disassembly and assembly
Refer to “front brake master cylinder assembly removal and installation” .
Disassembly
- Remove the reservoir cap (1), plate (2), diaphragm
(3) and reservoir tank (4).
- Remove the brake light switch (5) and brake lever
(6).
- Remove the dust boot (7) and push rod (8).
- Remove the snap ring (9).
- Remove the following parts from the master cylinder.
- Piston (10)
- return spring (11)
- return spring guide (12)
- Remove the dust rubber (13) and snap ring (14).
- Remove the connector (15), o-ring (16) and air
bleeder valve (17).
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)
- When install the spring guide, insert the spring guide
end “a” into the hole “b” of the master cylinder
- Apply grease to the push rod.
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)
- Apply grease to the brake lever pivot bolt.
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)
- Tighten the pivot bolt (1) and lock-nut (2) to the
specified torque.
Tightening torque
brake lever pivot bolt (a): 1 n·m (0.1 Kgf-m, 0.5
Lbf-ft)
brake lever pivot bolt lock-nut (b): 6 n·m (0.6
Kgf-m, 4.5 Lbf-ft)
- When installing the brake light switch, align the
projection “c” on the switch with the hole “d” in the
master cylinder.
Removal
Drain brake fluid. Refer to “brake fluid replacement” .
Disconnect the front brake light switch coupler (1).
Place a rag underneath the brake hose union bolt (2)
on the m ...
Refer to “front brake master cylinder / brake lever disassembly and assembly”
.
Master cylinder
Inspect the master cylinder bore for any scratches or
other damage
Piston / rubber parts
Insp ...
Other materials:
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Rear lighting system construction”
Special tool
...
Front brake caliper parts inspection
Refer to “front brake caliper disassembly and assembly” .
Brake caliper cylinder
Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any damage is found,
replace the caliper with a new one.
Brake caliper piston
Inspect the surface of brake caliper pistons for a ...
Rear brake disc inspection
Brake disc thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if defect is found.
Special tool
(a): 09900–20205 (micrometer (0 –
25 mm))
Brake disc thickness
service ...