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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:

Electrical parts connector / coupler
Faulty fi system is often related to poor electrical contact of connector/coupler. Before servicing individual electronic part, check electrical contact of the connector/coupler. When connecting a connector, be sure to push it in until a click is felt. With a lock type coupler ...

Specifications
Service data Wattage unit: w Tightening torque specifications Reference: for the tightening torque of fastener not specified in this section, refer to tightening torque list in section 0c . ...

Drive chain cleaning and lubricating
Clean and lubricate drive chain every 1 000 km (600 miles) Clean and lubricate the drive chain in the following procedures:  clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. Caution do not use trichloroethyle ...

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