Suzuki GSX-R 1000 Service Manual: Front brake caliper disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Brake / Front brakes / Repair instructions / 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.

Suzuki GSX-R. Front brake caliper disassembly and assembly

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.

Suzuki GSX-R. Front brake caliper disassembly and assembly

Remove the dust seals (2) and piston seals (3) from both sides of the caliper.

Suzuki GSX-R. Front brake caliper disassembly and assembly

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

wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or the others.

Suzuki GSX-R. Front brake caliper disassembly and assembly

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.

Suzuki GSX-R. Front brake caliper disassembly and assembly

When installing the spring to the caliper, bring its wider pawl “a” facing top side.

Suzuki GSX-R. Front brake caliper disassembly and assembly

Wider pawl
Top side

Install the brake pads and temporarily tighten the pad mounting pins (3).

Suzuki GSX-R. Front brake caliper disassembly and assembly

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:

Conrod crank pin bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. Place the plastigauge axially along ...

Fuses
The main fuse is located under the front seat. To access the fuse, remove the seat by referring to the seat lock and helmet holders. The fuses are located inside the left fairing. One 1 oa and one 15a spare fuses are provided inside the fuse box. They are designed to open when ...

Specifications
Service data Fi sensors Tightening torque specifications Reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c . ...