Front Brake Master Cylinder Assembly Removal And Installation - Suzuki GSX-R600 Manual

Front Brake Master Cylinder Assembly Removal
and Installation
Removal
1) Drain brake fluid. Refer to "Brake Fluid Replacement
(Page 4A-7)".
2) Disconnect the front brake light switch lead wire
coupler (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 brake hose union bolt (2) and
disconnect the brake hose.
5) Remove the master cylinder assembly (3).
B837H14106012
1
I837H1410022-01
2
I837H1410023-01
3
I837H1410024-01
Brake Control System and Diagnosis:
Installation
Install the front brake 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
handlebars (2) and tighten the upper holder bolt first.
Tightening torque
Master cylinder holder bolt (Upper and Lower)
(a): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
"B"
2
(a)
"C"
(a)
"C": Up mark
• After setting the brake hose union to the stopper,
tighten the union bolt (3) to the specified torque.
CAUTION
!
The seal washers should be replaced with the
new ones to prevent fluid leakage.
Tightening torque
Brake hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5
lb-ft)
4A-11
1
"A"
(a)
I837H1410025-01
"A"
1
"B"
2
" a "
I837H1410026-01
"a": Clearance