Suzuki GSX-R 1000 Service Manual: 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 fluid. Refer to “brake fluid replacement” in section 4a .
- Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.
| Note place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. |
- Remove the brake caliper by removing its mounting bolts (2).
Installation
Install the brake caliper in the reverse order of removal.
Pay attention to the following points:
- tighten each bolt to the specified torque.
Tightening torque front brake caliper mounting bolt (a): 39 n·m (3.9 Kgf-m, 28.0 Lbf-ft)
- After setting the brake hose union to the stopper, tighten the union bolt to the specified torque.
| Caution the seal washers should be replaced with the new ones to prevent fluid leakage. |
Tightening torque brake hose union bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)
- Bleed air from the brake system after installing the caliper. Refer to “air bleeding from brake fluid circuit” in section 4a .
- Check the brake fluid leakage and brake operation.
 Brake fluid, if it
Check the brake hose and hose joints for cracks and fluid leakage. |
Front brake pad replacement
Loosen the pad mounting pins (1).
Remove the brake caliper by removing the caliper
mounting bolts (2).
Remove the pad mounting pins (1), brake pads and
spring.
Caution ...
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 ...
Other materials:
Rear shock absorber adjustment
After installing the rear suspension, adjust the spring
pre-load and damping force as follows:
Spring pre-load adjustment
The set length 179.3 Mm (7.06 In) provides the
maximum spring pre-load.
The set length 189.3 Mm (7.45 In) provides the
minimum spring pre-load.
Std position
184.3 ...
Combination meter removal and installation
Removal
Remove the combination meter mounting bolt (1).
Bushing
Disconnect the coupler (2) and remove the
combination meter assembly (3).
Installation
Install the combination meter in the reverse order of
removal.
Note
fix the boot of ...
Ignition switch inspection
Inspect the ignition switch in the following procedures:
remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the ignition switch lead wire coupler (1).
Inspect the ignition switch for continuity with a tester.
If ...