Suzuki GSX-R 1000 Service Manual: Rear brake caliper removal and installation

Removal

1. Remove the rear wheel. Refer to “rear wheel assembly removal and installation” in section 2d .
2.  Drain brake fluid. Refer to “brake fluid replacement” in section 4a .
3.  Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.
4.  Remove the brake pads. Refer to “rear brake pad replacement” .

5. Remove the caliper by removing the sliding pin a (2).

6. Remove the caliper bracket (3) from the swingarm.

Installation

Install the brake caliper in the reverse order of removal.

Pay attention to the following points:

•  apply grease to the sliding pins.

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

• Tighten the caliper sliding pin a (1) to the specified torque.

Tightening torque rear brake caliper sliding pin a (a): 27 n·m (2.7 Kgf-m, 19.5 Lbf-ft)

• Fit each boot end into the sliding pin groove.

• Install the rear wheel. Refer to “rear wheel assembly removal and installation” in section 2d .
•  Install the brake pads. Refer to “rear brake pad replacement” .
•  After setting the brake hose union to the stopper, tighten the union bolt (2) to the specified torque.

Tightening torque brake hose union bolt (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

• Bleed air from the brake system after installing the caliper. Refer to “air bleeding from brake fluid circuit” in section 4a .
•  Check the brake fluid leakage and brake operation.

Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage.