Suzuki GSX-R 1000 Service Manual: 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 fluid. Refer to “brake fluid replacement” in section 4a .
- 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. |
- Remove the brake caliper by removing its mounting bolts (2).
Installation
Install the brake caliper in the reverse order of removal.
Pay attention to the following points:
- tighten each bolt to the specified torque.
Tightening torque front brake caliper mounting bolt (a): 39 n·m (3.9 Kgf-m, 28.0 Lbf-ft)
- After setting the brake hose union to the stopper, tighten the union bolt to the specified torque.
| Caution the seal washers should be replaced with the new ones to prevent fluid leakage. |
Tightening torque brake hose union bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)
- Bleed air from the brake system after installing the caliper. Refer to “air bleeding from brake fluid circuit” in section 4a .
- Check the brake fluid leakage and brake operation.
 Brake fluid, if it
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:
Front brake master cylinder components
Reservoir cap
Plate
Diaphragm
Reservoir tank
Master cylinder
Dust boot
Piston set
Brake lever
Brake lever pivot bolt
Brake lever pivot bolt lock-nut
Brake light switch
Brake hose union bolt
Brake hose
23 N·m (2.3 Kgf-m,
...
Rear brake master cylinder assembly removal and installation
Refer to “rear brake hose routing diagram” (page 4a-
2).
Removal
Remove the right side frame cover. Refer to “exterior parts removal and
installation” in section 9d .
Remove the rear brake fluid reservoir mounting bolt
(1).
Drain brake fluid. Refer to “brake fluid replac ...
Inspection after cleaning
For extended life of your motorcycle,
lubricate according to "general
lubrication" section .
Warning
Wet brakes can cause poor
braking performance and may
lead to an accident.
Avoid a possible accident by
expecting longer stopping distances
after washing your
...