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2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement

What you need

  1. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement, Front Brake Master Cylinder: step 1, image 1 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement, Front Brake Master Cylinder: step 1, image 2 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement, Front Brake Master Cylinder: step 1, image 3 of 3
    • Turn the bike off and allow it to fully cool. Put nitrile gloves on before beginning.

    • Use a 3/32 inch Allen key to remove the bolt securing the brake lever.

  2. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 2, image 1 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 2, image 2 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 2, image 3 of 3
    • Place a rag directly under the hose connection to catch any break fluid spills.

    • Use pliers to remove the clamp at the end of the reservoir hose.

    • Empty the brake fluid into an empty container.

  3. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 3, image 1 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 3, image 2 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 3, image 3 of 3
    • Use an 8 mm socket attached to a 3/8 inch ratchet to remove the two bolts.

  4. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 4, image 1 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 4, image 2 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 4, image 3 of 3
    • Grip the boot with your pliers and pull it out of its housing.

    • Use snap ring pliers to remove the snap ring behind the boot.

  5. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 5, image 1 of 1
    • Use pliers to pull out the spring and piston assembly.

  6. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 6, image 1 of 1
    • Check the condition of the master cylinder, and clean the cylinder with brake cleaner. Dry it with a rag.

    • If your master cylinder is corroded or in poor shape, you will need to buy a new or used master cylinder assembly and replace it.

  7. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 7, image 1 of 1
    • Fit the new seals onto the piston.

    • Use a bit of new brake fluid as lubrication.

  8. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 8, image 1 of 1
    • Place the new spring and piston back into the cylinder.

  9. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 9, image 1 of 1
    • 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.

    • Use pliers to push the assembly together.

  10. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 10, image 1 of 1
    • Replace the rubber boot.

  11. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 11, image 1 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 11, image 2 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 11, image 3 of 3
    • Use an 8 mm socket attached to a 3/8 inch ratchet to secure the two bolts.

    • Use pliers to pinch the clamp until it is in the right position like the photo.

    • Replace your brake lever, then tighten the single bolt using a 3/32 inch Allen key.

  12. 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 12, image 1 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 12, image 2 of 3 2006 Suzuki GSX-R600 Front Brake Master Cylinder Replacement: step 12, image 3 of 3
    • Remember to bleed the system while adding new fluid!

    • Refill the brake fluid reservoir to the appropriate level with new brake fluid.

    • Perform a quick test by pulling the brake lever and check that the front brake is functioning properly.

    • Congratulations! You are all done and ready to ride!

Conclusion

Your front brake is now working as intended!

prabhmeet sidhu

Member since: 01/17/22

205 Reputation

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