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Suzuki GSX-R 1000 Service Manual: Rear brake caliper disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Brake / Rear brakes / Repair instructions / Rear brake caliper disassembly and assembly

Refer to “rear brake caliper removal and installation” .

Disassembly

  1. Remove the pad spring (1) and rubber boot (2) from the caliper.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


  1. 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.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


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

Suzuki GSX-R. Rear brake caliper disassembly and assembly


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

Suzuki GSX-R. Rear brake caliper disassembly and assembly


Assembly

Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:

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.

Suzuki GSX-R. Rear brake caliper disassembly and assembly


Bf: brake fluid (dot 4)

: Grease 99000–25100 (suzuki
silicone grease or equivalent)

Suzuki GSX-R. Rear brake caliper disassembly and assembly


: 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)

Suzuki GSX-R. Rear brake caliper disassembly and assembly


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:

Front fork removal and installation
Note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal Remove the front wheel. Refer to “front wheel assembly removal and installation” in section 2d . ...

Location of labels
Read and follow all of the warnings labeled on your motorcycle. Make sure you understand all of the labels. Keep the labels on your motorcycle. Do not remove them for any reason. 1 Warning Keep windshield clean at all times.  Clean only with a soh cloth and warm ...

Water pump related parts inspection
Refer to “water pump disassembly and assembly” . Mechanical seal Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows indications of leakage. Oil seal Visually inspect the oil seal for damage, with p ...

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