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Suzuki GSX-R 1000 Service Manual: Front brake caliper removal and installation

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

  1. Drain brake fluid. Refer to brake fluid replacement in section 4a .
  2.  Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.
Note

place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.

Suzuki GSX-R. Front brake caliper removal and installation


  1. Remove the brake caliper by removing its mounting bolts (2).

Suzuki GSX-R. Front brake caliper removal and installation


Installation

Install the brake caliper in the reverse order of removal.

Pay attention to the following points:

Tightening torque front brake caliper mounting bolt (a): 39 nm (3.9 Kgf-m, 28.0 Lbf-ft)

Caution

the seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque brake hose union bolt (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Front brake caliper removal and installation


Brake fluid, if it
leaks, will interfere with safe running and discolor painted surfaces.

Check the brake hose and hose joints for cracks and fluid leakage.

Front brake pad replacement
Loosen the pad mounting pins (1).  Remove the brake caliper by removing the caliper mounting bolts (2).  Remove the pad mounting pins (1), brake pads and spring. Caution ...

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 ...

Other materials:

Cam chain tension adjuster inspection
The cam chain tension adjuster is maintained to proper tension automatically.  Remove the cam chain tension adjuster. Refer to engine top side disassembly .  Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body unt ...

Cam chain tensioner inspection
Inspect the cam chain tensioner in the following procedures:  remove the cam chain tensioner. Refer to cam chain guide / cam chain tensioner removal and installation .  Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new ...

Special tools and equipment
Recommended service material Note required service material is also described in the following. Clutch control system components  clutch components Special tool ...

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