Suzuki GSX-R 1000 Service Manual: Rear brake caliper disassembly and assembly
Refer to “rear brake caliper removal and installation” .
Disassembly
- Remove the pad spring (1) and rubber boot (2) from the caliper.
- 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. |
- Remove the dust seal (3) and piston seal (4).
- Remove the rubber boot (5), pad spring (6) and sliding pin b (7) from the bracket.
Assembly
Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:
- wash the caliper bore and piston with specified brake fluid. Particularly wash the dust seal groove and piston seal groove.
Bf: brake fluid (dot 4)
Caution
|
- Apply the brake fluid to dust seal (1).
Bf: brake fluid (dot 4)
- Apply grease to the piston seal (2).
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)
- Install the piston seal (2) as shown in the figure.
- Apply thread lock to the thread part and install the sliding pin b (3) to the bracket.
:
Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque rear caliper sliding pin b (a): 12 n·m (1.2 Kgf-m, 8.5 Lbf-ft)
- Install the rear brake caliper. Refer to “rear brake caliper removal and installation” .
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:
Water pump construction
Impeller
Mechanical seal
Oil seal
O-ring
O-ring
8
N·m (0.8 Kgf-m, 6.0 Lbf-ft)
10 N·m
(1.0 Kgf-m, 7.0 Lbf-ft)
Apply grease.
Apply engine coolant.
Apply molybdenum oil
solution.
Do not reuse.
...
Dtc “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204): primary
fuel injector circuit
malfunction
Detected condition and possible cause
Detected condition
Possible cause
Ckp signal is produced but fuel injector signal is
interrupted by 4 times or more continuity
Injector circuit open or short.
Injector malfunction.
Ecm malfunction.
...
Diagnostic information and procedures
Engine mechanical symptom diagnosis
Refer to “engine symptom diagnosis” in section 1a .
Compression pressure check
The compression pressure reading of a cylinder is a
good indicator of its internal condition.
The decision to overhaul the cylinder is often based on
the results of a compressio ...