Clutch Master Cylinder Assembly Removal And Installation - Suzuki 2005 GSF1200 Service Manual

5C-8 Clutch:
Clutch Master Cylinder Assembly Removal and
Installation
Removal
1) Drain clutch fluid. Refer to "Clutch Fluid
Replacement: ".
2) Disconnect the clutch lever position switch lead
wires (1).
1
3) Place a rag underneath the brake hose union bolt (2)
on the master cylinder to catch any spilt brake fluid.
4) Remove the clutch hose union bolt (2) and
disconnect the clutch hose.
5) Remove the left rear view mirror. (GSF1200)
6) Remove the master cylinder assembly.
Installation
Install the clutch master cylinder in the reverse order of
removal. Pay attention to the following points:
• When installing the master cylinder (1) onto the
handlebars (2), align the master cylinder holder's
mating surface "A" with the punch mark "B" on the
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handlebars (2) and tighten the upper holder bolt first.
Tightening torque
Clutch master cylinder holder bolt (a): 10 N·m (
1.0 kgf-m, 7.0 lb-ft)
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2
• After setting the clutch hose union to the stopper,
tighten the union bolt to the specified torque.
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Tightening torque
Clutch hose union bolt (b): 23 N·m (2.3 kgf-m,
16.5 lb-ft)
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• Bleed air from the clutch system. Refer to "Clutch
System Inspection: in Section 0B".
(a)
"A"
(a)
2
" c "
"B"
"a": Clearance
CAUTION
!
The seal washers should be replaced with the
new ones to prevent fluid leakage.
1
2
"B"
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1
"A"
" a "
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"c": "UP" mark
(b)
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