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:
Carrying a passenger
Carrying a passenger, when done
correctly, is a great way to share
the joy of motorcycling. You will
have to alter your riding style
somewhat since the extra weight
of a passenger will affect handling
and braking. You may also need
to adjust tire pressures and suspension;
please refer to the ...
Pair system inspection
Inspect pair system
every 12 000 km (7 500 miles, 24 months)
Inspect the pair (air supply) system periodically. Refer to “pair system
inspection” in section 1b .
Throttle valve synchronization
Inspect throttle valve synchronization
initially at 1 000 km (600 miles, 2 months) (e-33 only)
and ...
Clutch removal
Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Disconnect the ckp sensor coupler (1).
Remove the clutch cover (2).
...