Suzuki GSX-R 1000 Service Manual: 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 as that for the other side. |
Disassembly
- Remove the brake pads (1) and spring from the caliper by removing the pad mounting pins.
- Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air.
| Caution do not use high pressure air to prevent piston damage. |
- Remove the dust seals (2) and piston seals (3) from both sides of the caliper.
Assembly
Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:
- wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves.
Bf: brake fluid (dot 4)
Caution
|
- Apply the brake fluid to piston seals (1) and dust seals (2).
| Caution replace the piston seals (1) and dust seals (2) with new ones. |
Bf: brake fluid (dot 4)
- Install the piston seals as shown in the figure.Install the piston seals as shown in the figure.
- When installing the spring to the caliper, bring its wider pawl “a” facing top side.
|
- Install the brake pads and temporarily tighten the pad mounting pins (3).
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
Drain brake f ...
Front brake caliper parts inspection
Refer to “front 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 c ...
Other materials:
Headlight bulb and position light bulb
replacement
Caution
when you touch the bulb with your bare
hands, clean the bulb with a cloth moistened
with alcohol or soap water to prevent
premature bulb failure.
Low beam bulb
Remove the combination meter. Refer to “combination meter removal and
installation” in section 9c .
...
DTC “c15” (p0115-h/l): ect sensor circuit
malfunction
Detected condition and possible cause
Detected condition
Possible cause
C15
Output voltage is not with in the following
range.
0.15 V ≤ Sensor voltage < 4.85 V
Ect sensor circuit open or short.
Ect sensor malfunction.
Ec ...
Side-stand construction
Frame
Side-stand bracket
Washer
Side-stand
50 N·m (5.0 Kgf-m,
36.0 Lbf-ft)
40 N·m
(4.0 Kgf-m, 29.0 Lbf-ft)
Apply grease to sliding
surface.
...