GSX-R1000 K7/K8 Front master cylinder replacement procedure

Transcription

1 GSX-R000 K7/K8 Front master cylinder replacement procedure.preparation Replacement parts Part name P/NO Q ty Description Cylinder kit, FR MASTER RX0 Master cylinder set (5960-7H0) Bracket, reservoir tank (5975-7H00) Washer, brake hose ( ) Bolt, reservoir tank ( ) Nut, reservoir tank ( ) Nut, brake lever (57-09F00) Tool, oil Screwdriver (philips No. & flat blade No.) Hexagon socket wrench (mm),socket wrench(8, 0, mm),wrench (8, 0, mm),ratchet wrench, Extension bar for ratchet, Torque wrench(limit wrench),parts cleaner, Clear hose, Receptacle, Convex Brake Fluid (DOT) SUZUKI Silicone Grease (Part No ).Precautions Clean the motorcycle prior to this replacement. Dust or mud may cause adverse affect to the disassembled parts. When working with toxic or flammable materials, make sure that the area you work in is well ventilated. When removing the battery, disconnect the negative ( ) cable first and then the positive (+) cable. When or more persons work together, pay attention to the safety of each other. When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires. When removing parts that are to be reused, keep them arranged in an orderly manner so that they will be reinstalled in the proper order and orientation. When it is necessary to run the engine indoors, make sure that exhaust gas is discharged to outdoors. Refer to service manuals

2 . Procedure Remove the front master cylinder and reservoir tank NOTICE The brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage them severely. Immediately and completely wipe off any brake fluid then flush with water contacting any part of the motorcycle. ) Remove bolts() and Front seat() ) Remove the battery ( )lead wire() ) Disconnect the brake light switch lead wire coupler (). ) Place a rag underneath the brake hose union bolt(5) to catch any spilt brake fluid. 5

3 5) Remove the brake hose union bolt(5). NOTE Detach the cap(6) from new master cylinder then attach the cap to removed master cylinder due to prevent spilt brake fluid. 6 6) Remove the reservoir tank bracket bolt (7) and front master cylinder holder bolts (8). 7) Remove the front master cylinder(9) together with reservoir tank(0) ) Remove the brake light switch () and brake lever ().

4 . Reassembling the front master cylinder and reservoir tank Front Master Cylinder Components 9 (b) (f) 8 (d) 0 (c) (e) (c) (d) 5 (a) 6 7. Reservoir cap 9. Brake lever pivot bolt : 0 N m (.0 kgf-m, 7.0 lbf-ft). Plate 0. Brake lever pivot bolt lock-nut :. N m (0. kgf-m,.0 lbf-ft). Diaphragm. Brake light switch : 0.6 N m (0.06 kgf-m, 0. lbf-ft). Reservoir tank. Brake hose union bolt : Apply brake fluid. 5. Master cylinder. Brake hose : Apply silicone grease. 6. Dust boot : N m (. kgf-m, 6.5 lbf-ft) : Do not reuse. 7. Piston set : N m (0. kgf-m, 0.5 lbf-ft) 8. Brake lever : 6 N m (0.6 kgf-m,.5 lbf-ft)

5 Front Master Cylinder B a C VIEW B VIEW A a c d e b A e B A. Master cylinder A : Green paint b :. Reservoir tank B : Insert hose until shoulder of reservoir tank c :. Reservoir tank hose C : Insert hose until round shape d :.5. Clamp a : 90 e :.5mm NOTE New master cylinder is printed the green dot mark on the position A as shown in photo. A 5

6 Front Brake Hose Routing Diagram c B (a) (b) C (c) 5 (b) D A a b a (a) (a). Clamp : Clamp end should face downward. A : Clamp the brake hose firmly. : 0 N m (.0 kgf-m, 7.0 lbf-ft). Stopper : After the brake hose union has contacted to the stopper, tighten the union bolt. B : Pass the brake hose behind throttle cables. : 0.6 N m (0.06 kgf-m, 0. lbf-ft). Guide : Pass the brake hose into the hose guide.. Stopper : After positioning the clamp with the stopper, tighten the clamp bolt. C : Align the sleeve part of brake hose to clamp shape then set firmly. D : The black paint is right side and face upside. a : b : 5. Clamp : Insert the clamp end into the hole on the front fender. : N m (. kgf-m, 6.5 lbf-ft) c : 56 6

7 ) Apply silicone grease to contact surface of brake lever()and push rod B :GREASE (SUZUKI SILICONE GREASE ) ) Push rod B put in to the hole when assembling the brake lever() to the new master cylinder () ) Apply silicone grease to brake lever pivot bolt(). :GREASE (SUZUKI SILICONE GREASE) ) Tighten the brake lever pivot bolt () and lock-nut () to the specifued torque. Brake lever pivot bolt: N m (0. kgf-m, 0.5 lbf-ft) Brake lever pivot bolt lock-nut: 6 N m (0.6 kgf-m,.5 lbf-ft) B 5) Install the projection part of brake light switch(5) to front master cylinder. Tighten screw to the specified torque. Brake light switch screw:. N m (0. kgf-m,.0 lbf-ft) 5 6) Align C and punch mark D (6).when assmbling new master cylinder() to handle bar(6). Tighten upper bolt(7) first then tighten lower bolt(8).make sure the clearance. Tighten the master cylinder bolts to the specified torque. C D D C 7

8 NOTE Make sure UP mark E for upper 7 C Master cylinder holder bolt: 0 N m (.0 kgf-m, 7.0 lbf-ft) E D 8 Clearance 6 7) Install the new reservoir tank BKT(9).Tighten the new reservoir tank BKT bolt(0) to the specified torque. Reservoir tank bracket bolt: 0 N m (.0 kgf-m, 7.0 lbf-ft) 8) Install the new nut () ) Align the projection part of new reservoir tank and hole of new reservoir tank BKT(F). 9) Tighten the new reservoir tank bolt() to the specified torque. Reservoir tank bolt: 0.6 N m (0.06 kgf-m, 0. lbf-ft) F 0) Install the new washers(). NOTE Clean the seal washer() and brake hose union bolt() surface before assembling. ) Brake hose union attach to the stopper of front master cylinder. Tighten the brake hose union bolt() to the specified torque. Brake hose union bolt: N m (. kgf-m, 6.5 lbf-ft) ) Connect the brake light switch lead wire coupler (5) securely. 5 8

9 ) Connect the battery ( ) lead wire (6) securely. 6 ) Slide the front seat hooks into the seat hook retainers on the frame and tighten the bolts to the specified torque. Front seat bolt: 6 N m (0.6 kgf-m,.5 lbf-ft) 5. Front brake air bleeding Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by sponginess of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner: NOTICE Spilled brake fluid can damage painted surfaces and plastic parts. Be careful not to spill any fluid when filling the brake fluid reservoir. Wipe spilled fluid up and wash stained parts immediately. ) Place the motorcycle on a level surface and adjust the horizontal upper face of reservoir tank. 9

10 ) Remove the reservoir cap () and diaphragm. ) Fill the master cylinder reservoir to the upper line G. Specification and classification: DOT G NOTE While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. Slowly pour fluid to prevent air bubbles. Do not release brake lever when opening the air breeder valve. ) Pinch the reservoir hose by finger until all air in the hose has released. 5) Attach a clear hose () to the master cylinder air bleeder valve, and insert the free end of the hose into a receptacle. 6) Squeeze and release the brake lever several times in rapid succession then squeeze and hold the lever fully without releasing it. Loosen the air bleeder valve by turning it a /6 of a turn then tighten it. Repeat this process until the fluid flowing into the clear hose. 7) Squeeze and release the brake lever several times in rapid succession and squeeze and hold the lever fully without releasing it. Loosen the air bleeder valve by turning it a /6 of a turn then tighten it. Repeat this process until the fluid flowing into the clear hose no longer contains air bubbles. 0

11 8) Remove the clear hose (). 9) Attach a clear hose () to the left side brake caliper air bleeder valve, and insert the free end of the hose into a receptacle. 0) Squeeze and release the brake lever several times in rapid succession then squeeze and hold the lever fully without releasing it. Loosen the air bleeder valve by turning it a /6 of a turn then tighten it. Repeat this process until the clean fluid flowing into the clear hose. ) Squeeze and release the brake lever several times in rapid succession and squeeze and hold the lever fully without releasing it. Loosen the air bleeder valve by turning it a /6 of a turn then tighten it. ) Repeat 5 times for this process until the fluid flowing into the clear hose no longer contains air bubbles from air breeder valve. ) Remove the clear hose () ) Right side brake caliper air breeding after the same method 9)~) NOTE Fluid of reservoir tank amount should be use due to completely change to fresh fluid. 5) Attach a clear hose () to the master cylinder air bleeder valve, and insert the free end of the hose into a receptacle. 6) Squeeze and release the brake lever several times in rapid succession then squeeze and hold the lever fully without releasing it. Loosen the air bleeder valve by turning it a /6 of a turn then tighten it. 7) Repeat 5 times this process until the fluid flowing into the clear hose. 8) Confirm the brake lever feeling after air breeding. If lever feeling is still spongy, repeat again the air breeding from 9). 9)Remove the clear hose ().

12 0) Tighten the brake caliper and master cylinder air bleeder valve to the specified torque. Brake caliper air bleeder valve: 7.5 N m (0.75 kgf-m, 5.5 lbf-ft) Master cylinder air bleeder valve: 6 N m (0.6 kgf-m,.5 lbf-ft) ) Fill the reservoir with brake fluid to the upper line G of the reservoir. Specification and classification: DOT G ) Install the diaphragm and reservoir cap () and the plate () with a screw.

13 6. Inspection and confirmation after air breeding Check the each part assembling condition and part tightening Check the brake lever smooth operation Check the brake performance Adjust the clock Check the all electricity Refer to service manuals