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
|
- 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” .
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 ...
Rear brake caliper parts inspection
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:
Precautions
Precautions for engine cooling system
You can be injured by boiling fluid or steam if you open the
radiator cap when the engine is hot.
After the engine cools, wrap a thick cloth around cap and carefully
remove the cap by turning it a
quarter turn to allow pr ...
Brake fluid
Check the brake fluid level in both front and rear brake fluid reservoirs. If
the level in either reservoir is below the lower mark, inspect for brake pad
wear and leaks.
Warning
Brake fluid is harmful or fatal if
swallowed, and harmful if it
comes in contact with skin or
...
Oil pressure regulator / oil strainer
inspection
Refer to “oil pan / oil pressure regulator / oil strainer removal and
installation” .
Oil pressure regulator
Inspect the operation of the oil pressure regulator by
pushing the piston with a proper bar.
If the piston does not operate smoothly, replace the oil
pressure regulator with a new on ...