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

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

Suzuki GSX-R. Rear brake caliper disassembly and assembly

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

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

Suzuki GSX-R. Rear brake caliper disassembly and assembly

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:

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.

Suzuki GSX-R. Rear brake caliper disassembly and assembly

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.

Suzuki GSX-R. Rear brake caliper disassembly and assembly

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)

Suzuki GSX-R. Rear brake caliper disassembly and assembly

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:

Warning / caution / note
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could ...

Stp sensor removal and installation
Removal Remove the throttle body. Refer to “throttle body removal and installation” in section 1d (page 1d- 10). Remove the stp sensor (1) with the special tool. Special tool : 09930–11950 (torx wrench (5 mm)) Note prior to disassembly, mark the stp sensor’s origina ...

Rear brake disc inspection
Brake disc thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (a): 09900–20205 (micrometer (0 – 25 mm)) Brake disc thickness service ...