Suzuki GSX-R 1000 Service Manual: Front brake caliper disassembly and assembly
Refer to “front brake caliper removal and installation” .
| Note the right and left calipers are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side. |
Disassembly
- Remove the brake pads (1) and spring from the caliper by removing the pad mounting pins.
- Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air.
| Caution do not use high pressure air to prevent piston damage. |
- Remove the dust seals (2) and piston seals (3) from both sides of the caliper.
Assembly
Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:
- wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves.
Bf: brake fluid (dot 4)
Caution
|
- Apply the brake fluid to piston seals (1) and dust seals (2).
| Caution replace the piston seals (1) and dust seals (2) with new ones. |
Bf: brake fluid (dot 4)
- Install the piston seals as shown in the figure.Install the piston seals as shown in the figure.
- When installing the spring to the caliper, bring its wider pawl “a” facing top side.
|
- Install the brake pads and temporarily tighten the pad mounting pins (3).
Front brake caliper removal and installation
Note
the right and left calipers are installed
symmetrically and therefore the removal
procedure for one side is the same as that for
the other side.
Removal
Drain brake f ...
Front brake caliper parts inspection
Refer to “front brake caliper disassembly and assembly” .
Brake caliper cylinder
Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any damage is found,
replace the c ...
Other materials:
Side-stand / ignition interlock system parts
inspection
Check the interlock system for proper operation. If the
interlock system does not operate properly, check each
component for damage or abnormalities. If any
abnormality is found, replace the component with a new
one.
Side-stand switch
Turn the ignition switch off.
Remove the left si ...
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 ...
Wiring diagram
Refer to “wire color symbols” in section 0a .
For e-02, 19, 24, 51
For e-03, 28
For e-14, 33
...