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:
Engine coolant
Coolant level
The engine coolant solution
should be between "f" (full) and
"1..:' (Low) level lines on the engine
coolant reservoir. If the level is
lower than "1..:' (Low) level line,
bring it up to "f" (full) level by adding
50:50 mixture of distilled water ...
Precautions
Precautions for suspension
Refer to “general precautions” in section 00 (page 00-1).
All
suspensions, bolts and nuts are an important part in that it could
affect the performance of vital
parts. They must be tightened to the specified torque periodically and
if the suspension ...
Troubleshooting
This troubleshooting guide is provided
to help you find the cause of
some common complaints.
Caution
Failure to troubleshoot a problem
correctly can damage your
motorcycle. Improper repairs
or adjustments may damage
the motorcycle instead of fixing
it. Such damage may ...