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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 99000–25100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Rear brake caliper disassembly and assembly


: 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)

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:

Front wheel assembly removal and installation
Removal Remove the brake calipers, left and right. Caution do not operate the brake lever with the caliper removed. Loosen two axle pinch bolts (1) on the right front fork leg.  Remove the front axle bolt (2). Raise the front wheel off the ground a ...

Transmission related parts inspection
Refer to “transmission removal” , “transmission installation”  and “countershaft gear / driveshaft gear disassembly and assembly” . Gearshift fork to groove clearance Note the clearance for each gearshift fork plays an important role in the smoothness and positiveness of the ...

Cmp sensor removal and installation
Removal Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .  Remove the pair control solenoid valve. Refer to “pair control solenoid valve removal and installation” in section 1b .  Disconnect the coupler (1) and remove the cmp se ...

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