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 ...

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Schematic and routing diagram
Cooling circuit diagram Water hose routing diagram Thermostat air bleeder hole Cushion O-ring Radiator heat guard : be careful not to damage the pawls when removing. Yellow marking White marking Clamp end should face downward ...

Combination meter inspection
Led inspection Check that the leds “a” (fi, fuel, engine rpm, oil pressure/engine coolant, immobilizer (e-02, 19, 24, 51) and meter panel illumination) immediately light up when the ignition switch is turned on. Check that the other leds “b” (neutral, high-beam and turn signal indicator ligh ...

Headlight bulb and position light bulb replacement
Caution when you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. Low beam bulb Remove the combination meter. Refer to “combination meter removal and installation” in section 9c . ...