Suzuki GSX-R 1000 Service Manual: Brake system inspection

Suzuki GSX-R 1000 Service Manual / General information / Maintenance and lubrication / Repair instructions / Brake system inspection

Inspect brake system initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter

Inspect brake hose and brake fluid every 6 000 km (4 000 miles, 12 months)

The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers.

Never reuse brake fluid left over from the last servicing or stored for a long period of time.
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

Brake fluid level check

Keep the motorcycle upright and place the handlebars straight.
Check the brake fluid level by observing the lower limit line “a” on the front and rear brake fluid reservoirs. When the brake fluid level is below the lower limit line “a”, replenish with brake fluid that meets the following specification.

BF: brake fluid (dot 4)

Suzuki GSX-R. Brake fluid

Brake pads check

The extent of brake pad wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement” in section 4b and “rear brake pad replacement” in section 4c .

Caution

replace the brake pads as a set, otherwise braking performance will be adversely affected.

Suzuki GSX-R. Brake pads check

Front and rear brake hose inspection

Inspect the brake hoses and hose joints for crack, damage or brake oil leakage. If any defects are found, replace the brake hose with a new one. Refer to “front brake hose removal and installation” in section 4a and “rear brake hose removal and installation” in section 4a .

Suzuki GSX-R. Front and rear brake hose inspection

Brake pedal height inspection and adjustment

Inspect the brake pedal height “a” between the pedal top face and footrest.
Adjust the brake pedal height if necessary.

Brake pedal height “a” standard: 65 – 75 mm (2.6 – 3.0 In)

Loosen the lock-nut (1).
Turn the push rod (2) until the brake pedal becomes 65 – 75 mm (2.6 – 3.0 In) “a” below the top of the footrest.
Tighten the lock-nut (1) securely.

Tightening torque rear master cylinder rod lock-nut (a): 17 n·m ( 1.7 Kgf-m, 12.5 Lbf-ft)

Suzuki GSX-R. Brake pedal height inspection and adjustment

Brake hose replacement

Replace brake hose every 4 years

Refer to “front brake hose removal and installation” in section 4a and “rear brake hose removal and installation” in section 4a .

Brake fluid replacement

Replace brake fluid every 2 years

Refer to “brake fluid replacement” in section 4a .

Air bleeding from brake fluid circuit

Refer to “air bleeding from brake fluid circuit” in section 4a Rear brake light switch adjustment

Refer to “rear brake light switch inspection and adjustment” in section 4a .

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 ...

Tire inspection

Inspect tire every 6 000 km (4 000 miles, 12 months) Tire tread condition Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous s ...

Other materials:

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 caliper with a new one. Brake caliper piston Inspect the brake caliper piston surface for any s ...

Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the national highway traffic safety administration (nhtsa) in addition to notifying american suzuki motor corp. If nhtsa receives similar complaints, it ma ...

Gear position (gp) switch removal and installation
Removal Turn the ignition switch off. Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). Disconnect the gear position switch lead wire coupler (1). Remove the engine sprocket cover. Refer to “engine sprocket r ...