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:
Side stand
An interlock switch is provided to
cut off the ignition circuit when the
side stand is down and the transmission
is in any gear other than
neutral.
The side stand/ignition interlock
switch works as follows:
if the side stand is down and
the transmission is in gear, the
engine ...
Generator removal and installation
Removal
Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
Remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Disconnect the generator coupler (1).
Remove the generator cover (2).
...
Throttle valve synchronization
Check and adjust the throttle valve synchronization
among four cylinders.
Start the engine and run it in idling condition
for
warming up.
Stop the warmed-up engine.
Lift and support the fuel tank. Refer to “fuel
tank
removal and installation” in section 1g (page ...