How to Rebuild Suzuki GSX-R1000 Front Brake Calipers
The secret to a successful brake caliper rebuild is keeping everything as clean as possible, because even a little dirt can negatively affect the braking system.
Rebuilding both sides of the front brake calipers at the same time on a Suzuki GSX-R1000 is highly recommended. The wear on the calipers will be the same on either side, so if one caliper needs rebuilding, the other one will too. You can either get a piston set that includes the piston seals and the pistons, or a piston seal set that only includes the seals, depending on the condition of your GSXR’s brakes. Watch the video above and follow the steps below to rebuild a Suzuki GSXR’s brake calipers.
Tools and Parts Needed – Suzuki GSXR Front Caliper Rebuild
- Ratchet and extension
- 12mm socket
- 5mm Allen
- T40 Torx
- 8mm wrench
- Pick tool
- Torque wrench
Rebuilding Suzuki GSX-R1000 Front Brake Calipers
Step 1. Remove the brake line union bolt from the caliper assembly, and have a container or some rags ready beneath the caliper to catch brake fluid spills.
NOTE: Brake fluid will damage paintwork, plastics and decals. Be careful when handling brake fluid, and have plenty of rags or shop towels ready in case of any spills.
Step 2. Loosen the two brake pad pins, then remove the two caliper mounting bolts and pull the caliper assembly off the brake rotor.
Step 3. Remove the two brake pad pins, followed by the brake pads and the pad spring.
PRO TIP: If you’re reinstalling the pads, make sure to keep them clean and avoid getting any brake fluid on them.
Step 4. Thoroughly clean the brake caliper assembly with brake/contact cleaner.
NOTE: Cleaning the caliper before disassembling it minimizes the chances of any dirt getting inside the caliper and contaminating the brake system.
Step 5. Remove the bleed valve and the three Torx bolts, and separate the two halves of the caliper.
NOTE: If your brake piston set includes the O-ring that sits between the caliper halves, you can discard the old O-ring. Otherwise, save the O-ring for when you reassemble the caliper.
Step 6. Remove the two brake pistons, and the inner and outer piston seals, from each half of the caliper.
Step 7. Thoroughly clean the inside of the caliper with brake/contact cleaner, then coat the inside surfaces of the caliper with brake fluid.
Step 8. Make sure all the parts (and your hands) are completely clean, then install the new inner and outer piston seals.
Step 9. Install the new brake pistons, or reinstall the old pistons if you’re only replacing the piston seals.
Step 10. Install the new O-ring (or reinstall the old O-ring) between the caliper halves, and bolt them back together again. Next, reinstall the bleed valve and torque the caliper bolts to 16 foot-pounds.
Step 11. Clean off any brake fluid from the outside of the caliper assembly.
PRO TIP: Put your finger over the hole for the brake line to stop any cleaner from getting inside the caliper.
Step 12. Reconnect the brake line to the caliper assembly, and clean away any remaining brake fluid from the brake line and caliper. Torque the brake line union bolt to 16.5 foot-pounds.
Step 13. Reinstall the caliper spring, the brake pads and the pad pins, then torque the pad pins to 11.5 foot-pounds.
PRO TIP: Now is an ideal time to replace the brake pads with new Suzuki GSX-R1000 brake pads.
Step 14. Slide the caliper assembly back over the brake rotor, and reinstall the two caliper mounting bolts. Torque the caliper mounting bolts to 28 foot-pounds.
After one of your Suzuki GSX-R1000’s front brake calipers (left or right) is rebuilt, repeat the process on the other side before bleeding the system and you’ll be done.
If you’re going to bleed the brakes on your motorcycle after rebuilding the calipers, watch the video above to see how to bleed the brakes on a Suzuki GSXR.