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Suzuki GSX-R 1000 Service Manual: Rear brake caliper disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Brake / Rear brakes / Repair instructions / Rear brake caliper disassembly and assembly

Refer to rear brake caliper removal and installation .

Disassembly

  1. Remove the pad spring (1) and rubber boot (2) from the caliper.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


  1. Place a rag over the piston to prevent it from popping out and then force out the piston using compressed air.
Caution

do not use high pressure air to prevent piston damage.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


  1. Remove the dust seal (3) and piston seal (4).

Suzuki GSX-R. Rear brake caliper disassembly and assembly


  1. Remove the rubber boot (5), pad spring (6) and sliding pin b (7) from the bracket.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


Assembly

Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:

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.
  •  Replace the piston seal and dust seal with new ones.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


Bf: brake fluid (dot 4)

: Grease 9900025100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Rear brake caliper disassembly and assembly


: Thread lock cement
9900032110 (thread lock cement super 1322 or equivalent)

Tightening torque rear caliper sliding pin b (a): 12 nm (1.2 Kgf-m, 8.5 Lbf-ft)

Suzuki GSX-R. Rear brake caliper disassembly and assembly


Rear brake caliper removal and installation
Removal Remove the rear wheel. Refer to rear wheel assembly removal and installation in section 2d .  Drain brake fluid. Refer to brake fluid replacement in section 4a .  Remo ...

Rear brake caliper parts inspection
Refer to rear 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 ca ...

Other materials:

Steering damper maintenance
Keep the steering damper shaft 1 clean at all times.  Wipe off any oil residue with a cloth. Do not confuse the grease-like residue on the steering damper's shaft with an oil leak. Collection of this residue is normal and is from oil seal lubricant used in the damper. Yo ...

Batiery
The battery is located under the front seat. Remove the front seat by referring to the seat lock and helmet holders section. This battery is sealed type and requires no maintenance. Have your dealer check the battery's state of charge periodically. The standard charging rate is 1.2A x ...

Fuel level gauge inspection
Inspect the fuel level gauge in the following procedures:  remove the fuel pump. Refer to fuel pump disassembly and assembly in section 1g .  Measure the resistance at each fuel level gauge in float position. If the resistance is incorrect, replace fuel level gauge with a ne ...

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