Suzuki GSX-R 1000 Service Manual: Rear brake caliper disassembly and
assembly
Refer to “rear brake caliper removal and installation” .
Disassembly
- Remove the pad spring (1) and rubber boot (2) from
the caliper.

- Place a rag over the piston to prevent it from popping
out and then force out the piston using compressed
air.
Caution
do not use high pressure air to prevent
piston damage. |

- Remove the dust seal (3) and piston seal (4).

- Remove the rubber boot (5), pad spring (6) and
sliding pin b (7) from the bracket.

Assembly
Assemble the caliper in the reverse order of
disassembly. Pay attention to the following points:
- wash the caliper bore and piston with specified brake
fluid. Particularly wash the dust seal groove and
piston seal groove.
Bf: brake fluid (dot 4)
Caution
- wash the caliper components with fresh
brake fluid before reassembly. Never use
cleaning solvent or gasoline to wash them.
- Do not wipe the brake fluid off after
washing the components.
- When washing the components, use the
specified brake fluid. Never use different
types of fluid or cleaning solvent such as
gasoline, kerosine or the others.
- Replace the piston seal and dust seal with
new ones.
|

- Apply the brake fluid to dust seal (1).
Bf: brake fluid (dot 4)
- Apply grease to the piston seal (2).
: Grease 99000–25100 (suzuki
silicone
grease or equivalent)
- Install the piston seal (2) as shown in the figure.

- Apply thread lock to the thread part and install the
sliding pin b (3) to the bracket.
:
Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque
rear caliper sliding pin b (a): 12 n·m (1.2 Kgf-m,
8.5 Lbf-ft)

- Install the rear brake caliper. Refer to “rear brake caliper removal and
installation” .
Removal
Remove the rear wheel. Refer to “rear wheel assembly removal and
installation” in section 2d .
Drain brake fluid. Refer to “brake fluid replacement” in section 4a .
Remo ...
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 ca ...
Other materials:
Radiator reservoir tank removal and
installation
Removal
Remove the right side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Disconnect the reservoir tank inlet hose (1) from the
reservoir tank (2) and drain the engine coolant.
Remove the reservoir tank (2).
Disconnect the reservoir tank ove ...
Schematic and routing diagram
Engine lubrication system chart diagram
Engine lubrication circuit diagram
...
Specifications
Service data
Fi sensors
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Exhaust control system construction” “exhaust system components”
Reference: for the tightening torque of fastener not specified in this ...