Suzuki GSX-R 1000 Service Manual: 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 .
- Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.
- Remove the brake pads. Refer to “rear brake pad replacement” .
| Note place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. |
- Remove the caliper by removing the sliding pin a (2).
- 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.
| Caution the seal washers should be replaced with the new ones to prevent fluid leakage. |
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
Check the brake hose and hose joints for cracks and fluid leakage. |
Rear brake pad replacement
Remove the plug (1) and brake pad mounting pin (2).
Remove the brake pads (3).
Caution
do not operate the brake pedal while the
pads are removed.
Clean up the ...
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 pop ...
Other materials:
Precautions
Precautions for engine electrical device
Refer to “general precautions” in section 00 (page 00-1) and “precautions for
electrical circuit service” in section 00
(page 00-2).
Component location
Engine electrical components location
Refer to “electrical components location” in section 0a .
Dia ...
Crankshaft thrust clearance inspection and
selection
Refer to “engine bottom side disassembly” (page 1d-
49).
Refer to “engine bottom side assembly” .
Inspection
With the crankshaft’s right-side and left-side thrust
bearings inserted into the upper crankcase.
Measure the thrust clearance “a” between the leftside
thrust bearing and ...
Generator removal and installation
Removal
Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
Remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Disconnect the generator coupler (1).
Remove the generator cover (2).
...