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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:

Air cleaner
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Side stand
An interlock switch is provided to cut off the ignition circuit when the side stand is down and the transmission is in any gear other than neutral. The side stand/ignition interlock switch works as follows:  if the side stand is down and the transmission is in gear, the engine ...

Exhaust control system description
The exhaust control system (excs) consists of the exhaust control valve (excv), exhaust control valve actuator (excva) and exhaust control valve cables (excv cables). Excv is installed in the exhaust pipe. Excva is mounted inside of the right frame. The excv is operated by the excva via the ...

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