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:
General precautions
Proper service and repair procedures are
important for the safety of the service
mechanic and the safety and reliability of
the motorcycle.
When 2 or more persons work together,
pay attention to the safety of each other.
When it is necessary to run the ...
Loading guidelines
This motorcycle is primarily
intended to carry small items
when you are not riding with a
passenger. Follow the guidelines
below to carry a passenger or
cargo:
balance the load between the
left and right side of the motorcycle
and fasten it securely.
Place cargo weight as ...
Ecm / various sensors
Since each component is a high-precision part, great
care should be taken not to apply any severe impacts
during removal and installation.
Be careful not to touch the electrical terminals of the
electronic parts (ecm, etc.). The static electricity from
your body may damage them. ...