Introduction
This guide demonstrates how to change a front brake master cylinder on a 2006 Suzuki GSX-R600. This repair might be needed if your brake lever is touching your handlebar when depressed. This is not the easiest process, but by following this guide, you should be able to do it on your own and save some money! Check the tools section for required tools. Purchase a new master cylinder if yours is damaged and/or old.
You'll need a bit of patience, as this repair can take some time. Be patient and follow the steps carefully.
Before beginning, make sure your bike is off and fully cool, then throw on a pair of nitrile gloves.
What you need
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Use a 3/32 inch Allen key to remove the bolt securing the brake lever.
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Place a rag directly under the hose connection to catch any break fluid spills.
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Use pliers to remove the clamp at the end of the reservoir hose.
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Empty the brake fluid into an empty container.
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Grip the boot with your pliers and pull it out of its housing.
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Use snap ring pliers to remove the snap ring behind the boot.
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Check the condition of the master cylinder, and clean the cylinder with brake cleaner. Dry it with a rag.
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While holding the piston and spring down, use snap ring pliers to place the snap ring in the same orientation that it was taken out.
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Use pliers to push the assembly together.
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Use an 8 mm socket attached to a 3/8 inch ratchet to secure the two bolts.
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Use pliers to pinch the clamp until it is in the right position like the photo.
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Replace your brake lever, then tighten the single bolt using a 3/32 inch Allen key.
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Refill the brake fluid reservoir to the appropriate level with new brake fluid.
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Perform a quick test by pulling the brake lever and check that the front brake is functioning properly.
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Your front brake is now working as intended!
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