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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

  1. 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


  1. 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


  1. 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:

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


Caution

replace the piston seals (1) and dust seals (2) with new ones.

Bf: brake fluid (dot 4)

Suzuki GSX-R. Front brake caliper disassembly and assembly


Suzuki GSX-R. Front brake caliper disassembly and assembly


  1. Wider pawl
  2. Top side

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:

Dimmer / passing light switch inspection
Inspect the dimmer/passing light switch in the following procedures:  remove the air cleaner box. Refer to air cleaner box removal and installation in section 1d .  Disconnect the left handlebar switch coupler (1). (Yellow) Inspect the dimmer/passing light switch ...

Rear brake caliper parts inspection
Refer to rear 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 caliper with a new one. Brake caliper piston Inspect the brake caliper piston surface for any s ...

Pair system inspection
Inspect pair system every 12 000 km (7 500 miles, 24 months) Inspect the pair (air supply) system periodically. Refer to pair system inspection in section 1b . Throttle valve synchronization Inspect throttle valve synchronization initially at 1 000 km (600 miles, 2 months) (e-33 only) and ...

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