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:
Specifications
Service data
Wheel
unit: mm (in)
Tire
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Front wheel components” “front wheel assembly construction”
“rear wheel components” “rear wheel assembly c ...
Combination meter inspection
Led inspection
Check that the leds “a” (fi, fuel, engine rpm, oil
pressure/engine coolant, immobilizer (e-02, 19, 24, 51)
and meter panel illumination) immediately light up when
the ignition switch is turned on.
Check that the other leds “b” (neutral, high-beam and
turn signal indicator ligh ...
Tire removal and installation
Removal
The most critical factor of a tubeless tire is the seal
between the wheel rim and the tire bead. For this
reason, it is recommended to use a tire changer that can
satisfy this sealing requirement and can make the
operation efficient as well as functional.
Removal the wheel ass ...