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Suzuki GSX-R 1000 Service Manual: Brake system inspection

Inspect brake system initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter

Inspect brake hose and brake fluid every 6 000 km (4 000 miles, 12 months)


  • The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers.

    Never reuse brake fluid left over from the last servicing or stored for a long period of time.

  • Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

Brake fluid level check

  1. Keep the motorcycle upright and place the handlebars straight.
  2. Check the brake fluid level by observing the lower limit line “a” on the front and rear brake fluid reservoirs. When the brake fluid level is below the lower limit line “a”, replenish with brake fluid that meets the following specification.

BF: brake fluid (dot 4)

Suzuki GSX-R. Brake fluid


Suzuki GSX-R. Brake fluid


Brake pads check

The extent of brake pad wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement” in section 4b  and “rear brake pad replacement” in section 4c .

Caution


replace the brake pads as a set, otherwise braking performance will be adversely affected.

Suzuki GSX-R. Brake pads check


Suzuki GSX-R. Brake pads check


Front and rear brake hose inspection

Inspect the brake hoses and hose joints for crack, damage or brake oil leakage. If any defects are found, replace the brake hose with a new one. Refer to “front brake hose removal and installation” in section 4a  and “rear brake hose removal and installation” in section 4a .

Suzuki GSX-R. Front and rear brake hose inspection


Suzuki GSX-R. Front and rear brake hose inspection


Brake pedal height inspection and adjustment

  1. Inspect the brake pedal height “a” between the pedal top face and footrest.

    Adjust the brake pedal height if necessary.

Brake pedal height “a” standard: 65 – 75 mm (2.6 – 3.0 In)

  1. Loosen the lock-nut (1).
  2.  Turn the push rod (2) until the brake pedal becomes 65 – 75 mm (2.6 – 3.0 In) “a” below the top of the footrest.
  3.  Tighten the lock-nut (1) securely.

Tightening torque rear master cylinder rod lock-nut (a): 17 n·m ( 1.7 Kgf-m, 12.5 Lbf-ft)

Suzuki GSX-R. Brake pedal height inspection and adjustment


Brake hose replacement

Replace brake hose every 4 years

Refer to “front brake hose removal and installation” in section 4a  and “rear brake hose removal and installation” in section 4a .

Brake fluid replacement

Replace brake fluid every 2 years

Refer to “brake fluid replacement” in section 4a .

Air bleeding from brake fluid circuit

Refer to “air bleeding from brake fluid circuit” in section 4a Rear brake light switch adjustment

Refer to “rear brake light switch inspection and adjustment” in section 4a .

Drive chain cleaning and lubricating
Clean and lubricate drive chain every 1 000 km (600 miles) Clean and lubricate the drive chain in the following procedures:  clean the drive chain with kerosine. If the drive chain tends ...

Tire inspection
Inspect tire every 6 000 km (4 000 miles, 12 months) Tire tread condition Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous s ...

Other materials:

Conrod crank pin bearing removal and installation
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Removal Remove the conrod crank pin bearings (1). Note  do not remove the bearings (1) unless absolutely necessary.  Make a note of where the bearings are removed ...

Cooling fan inspection
Cooling fan operating temperature standard (on → off): approx. 100 ?‹C (212 ƒ‹f) (off → on): approx. 105 ?‹C (221 ƒ‹f) Inspect the cooling fan in the following procedures:  disconnect the cooling fan motor coupler (1). Test the cooling fan motor for load ...

Modification
Modification of the motorcycle, or removal of original equipment may render the vehicle unsafe or illegal. Obey all applicable equipment regulations in your area. The frame of this motorcycle is made of an aluminum alloy. Therefore, never make any modifications such as drilling or weldin ...

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