MOTORCYCLE

DATE: Sep 24, 2003

PAGE: 1 OF 16

SUBJECT: SERVICE INFORMATION

APPLICABLE MODEL:GSX-R1000K4
EFFECTIVE ENGINE OR FRAME NO.:
REFERENCE: E-02, 03, 19, 24, 28, 33

This bulletin is to inform you of the service information for the GSX-R1000K4 model. Please
use the following service manual along with the information contained in this bulletin for
properly servicing GSX-R1000K4 model.

GSX-R1000 SERVICE MANUAL: 99500-39240-01E

99500-39240-01F
99500-39240-01G
99500-39240-01B
99500-39240-03E
99500-39240-01S

We hope that this information will be useful in your service activities.

CONTENTS
PAGE
SPECIFICATIONS.................................................................................... 2
SERVICE DATA ....................................................................................... 3
PERIODIC MAINTENANCE CHART .......................................................14
FRONT BRAKE........................................................................................15

NOTE:
The specifications are the same as K3-MODEL.
Asterisk mark (*) indicates the New K4-model service data.

SUZUKI MOTOR CORPORATION

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 070 mm (81.5 in)
Overall width ....................................................................................... 715 mm (28.1 in)
Overall height ...................................................................................... 1 145 mm (45.1 in)
Wheelbase .......................................................................................... 1 410 mm (55.5 in)
Ground clearance................................................................................ 130 mm (5.1 in)
Seat height. ......................................................................................... 830 mm (32.7 in)
Dry mass ............................................................................................. 168 kg (370 lbs)
168 kg (372 lbs) .......E-33

ENGINE
Type .................................................................................................... Four-stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................ 4
Bore..................................................................................................... 73.0 mm (2.874 in)
Stroke .................................................................................................. 59.0 mm (2.323 in)
Displacement ...................................................................................... 988 cm3 (60.3 cu. in)
Compression ratio ............................................................................... 12.0 : 1
Fuel system. ........................................................................................ Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system ..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 150 ± 100 r/min

DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio ........................................................................ 1.553 (73/47)
Gear ratios, Low .................................................................................. 2.687 (43/16)
2nd ................................................................................... 2.052 (39/19)
3rd .................................................................................... 1.681 (37/22)
4th .................................................................................... 1.450 (29/20)
5th .................................................................................... 1.304 (30/23)
Top ................................................................................... 1.208 (29/24)
Final reduction ratio............................................................................. 2.470 (42/17)
Drive chain .......................................................................................... DID530, 110 links

CHASSIS
Front suspension................................................................................. Inverted telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 120 mm (4.7 in)
Rear wheel travel. ............................................................................... 130 mm (5.1 in)
Steering angle ..................................................................................... 27°
Caster.................................................................................................. 23.5°
Trail ..................................................................................................... 91 mm (3.58 in)
Turning radius ..................................................................................... 3.4 m (11.2 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70ZR17 M/C (58W), tubeless
Rear tire size ....................................................................................... 190/50ZR17 M/C (73W), tubeless

ELECTRICAL
Ignition type ......................................................................................... Electronic ignition (Transistorized)
Ignition timing. ..................................................................................... 8° B.T.D.C. at 1 150 r/min...... #1·4
4° B.T.D.C. at 1 150 r/min...... #2·3
Spark plug ........................................................................................... NGK CR9E or DENSO U27ESR-N
Battery ................................................................................................. 12V 36.0 kC (10 Ah) /10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse............................................................................................. 30A
Fuse .................................................................................................... 15/15/10/10/10/10A........ E-03, 24, 28, 33
15/15/10/10/10/10A........ E-02, 19
Headlight ............................................................................................. 12V 55W (H7) + 12V60/55W (H4)
Turn signal light ................................................................................... 12V 18W
License plate light ............................................................................... 12V 5W
Brake light/Taillight .............................................................................. 12V 21/5W
Speedometer light ............................................................................... LED
Tachometer light ................................................................................. LED
Neutral indicator light .......................................................................... LED
High beam indicator light..................................................................... LED
Turn signal indicator light .................................................................... LED
Position/Parking light........................................................................... 12V 5W ......Except E-03, 24, 28, 33
Oil pressure/Coolant temperature/Fuel injection warning light............ LED
Fuel level indicator light....................................................................... LED
Engine RPM indicator light .................................................................. LED

CAPACITIES
Fuel tank, including reserve ............................................................... 8.5 L (4.8/4.0 US/Imp gal)
Engine oil, oil change ......................................................................... 3 000 ml (3.2/2.6 US/Imp qt)
with filter change ............................................................... 3 300 ml (3.5/2.9 US/Imp qt)
overhaul. ........................................................................... 3 600 ml (3.8/3.2 US/Imp qt)
Coolant ................................................................................................ 2 400 ml (2.5/2.1 US/Imp qt)

These specifications are subject to change without notice.

–2–
SERVICE DATA
VALVE + VALVE GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. 29
IN. ----
(1.14)
24
EX. ----
(0.94)
Tappet clearance (when cold) 0.10 – 0.20
IN. ----
(0.004 – 0.008)
0.20 – 0.30
EX. ----
(0.008 – 0.012)
Valve guide to valve stem 0.010 – 0.037
IN. ----
clearance (0.0004 – 0.0015)
0.030 – 0.057
EX. ----
(0.0012 – 0.0022)
Valve guide I.D. 4.000 – 4.012
IN. & EX. ----
(0.1575 – 0.1580)
Valve stem O.D. 3.975 – 3.990
IN. ----
(0.1565 – 0.1571)
3.955 – 3.970
EX. ----
(0.1557 – 0.1563)
Valve stem deflection 0.35
IN. & EX. ----
(0.014)
Valve stem runout 0.05
IN. & EX. ----
(0.002)
Valve head thickness 0.5
IN. & EX. ----
(0.02)
Valve seat width 0.9 – 1.1
IN. & EX. ----
(0.035 – 0.043)
Valve head radial runout 0.03
IN. & EX. ----
(0.001)
Valve spring free length 37.0
IN. & EX. ----
(1.46)
Valve spring tension 127 – 147 N (13.0 – 15.0 kgf)
IN. & EX. (28.7 – 33.1 lbs) ----
at length 32.85 mm (1.29 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height 37.01 – 37.06 36.71
IN.
(1.457 – 1.459) (1.445)
35.98 – 36.03 35.68
EX.
(1.417 – 1.418) (1.405)
Camshaft journal oil clearance 0.032 – 0.066 0.150
IN. & EX.
(0.0013 – 0.0026) (0.0059)

–3–
 ITEM STANDARD LIMIT
Camshaft journal holder I.D. 24.012 – 24.025
IN. & EX. ----
(0.9454 – 0.9459)
Camshaft journal O.D. 23.959 – 23.980
IN. & EX. ----
(0.9433 – 0.9441)
Camshaft runout 0.10
----
(0.004)
Cam chain pin (at arrow “3”) 14th pin ----
Cylinder head distortion 0.20
----
(0.008)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 000 kPa
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi) (
10 kgf/cm²,
142 psi )
Compression pressure 200 kPa
difference ----
( 2 kgf/cm²,
28 psi )
Piston to cylinder clearance 0.030 – 0.040 0.120
(0.0012 – 0.0016) (0.0047)
Cylinder bore 73.000 – 73.015 Nicks or
(2.8740 – 2.8746) Scratches
Piston diam. 72.965 – 72.980
72.880
(2.8726 – 2.8732)
(2.8693)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion 0.02
----
(0.008)
Piston ring free end gap 6.4
1st R Approx 8.0 (0.31)
(0.25)
8.2
2nd RN Approx 10.2 (0.40)
(0.32)
Piston ring end gap 0.06 – 0.18 0.50
1st R
(0.002 – 0.007) (0.020)
0.06 – 0.18 0.50
2nd RN
(0.002 – 0.007) (0.020)
Piston ring to groove clearance 0.180
1st ----
(0.0071)
0.150
2nd ----
(0.0059)
Piston ring groove width 1.01 – 1.03
1st ----
(0.0398 – 0.0406)
0.81 – 0.83
2nd ----
(0.0319 – 0.0327)
1.51 – 1.53
Oil ----
(0.0594 – 0.0602)

–4–
 ITEM STANDARD LIMIT
Piston ring thickness 0.97 – 0.99
1st ----
(0.0382 – 0.0390)
0.77 – 0.79
2nd ----
(0.0303 – 0.0311)
Piston pin bore I.D. 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.95 – 20.00
----
(0.7854 – 0.7874)
Crank pin width 20.10 – 20.15
----
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 34.976 – 35.000
----
(1.3770 – 1.3780)
Crankshaft journal oil clearance 0.016 – 0.040 0.080
(0.0006 – 0.0016) (0.0031)
Crankshaft journal O.D. 34.976 – 35.000
----
(1.3770 – 1.3780)
Crankshaft thrust bearing 2.420 – 2.440
Right side ----
thickness (0.0953 – 0.0961)
2.360 – 2.500
Left side ----
(0.0929 – 0.0984)
Crankshaft thrust clearance 0.070 – 0.110
----
(0.0028 – 0.0043)
Crankshaft runout 0.05
----
(0.002)

BALANCER Unit: mm (in)

ITEM STANDARD LIMIT
Balancer shaft journal oil clearance 0.020 – 0.044 0.080
(0.00079 – 0.00173) (0.00315)
Balancer shaft journal O.D. 22.984 – 23.000
----
(0.9049 – 0.9055)

–5–
OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) 100 – 400 kPa
(1.0 – 4.0 kgf/cm², 14 – 57 psi) ----
at 3 000 r/min.

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch lever play 10 – 15
----
(0.4 – 0.6)
Clutch release screw 1/4 turn back ----
Drive plate thickness 2.45 – 2.95 2.15
No. 1, 2 and 3
(0.096 – 0.116) (0.085)
Drive plate claw width 13.85 – 13.96 13.05
No. 1, 2 and 3
(0.5453 – 0.5496) (0.5138)
Driven plate distortion 0.10
----
(0.004)
Clutch spring free height 77.77 73.9
(3.062) (2.909)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 1.553 (73/47) ----
Final reduction ratio 2.470 (42/17) ----
Gear ratios Low 2.687 (43/16) ----
2nd 2.052 (39/19) ----
3rd 1.681 (37/22) ----
4th 1.450 (29/20) ----
5th 1.304 (30/23) ----
Top 1.208 (29/24) ----
Shift fork to groove clearance 0.10 – 0.30 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1
----
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9
----
(0.189 – 0.193)
Drive chain Type DID530 ----
Links 110 links ----
319.4
20-pitch length ----
(12.57)
Drive chain slack (on side-stand) 20 – 30
----
(0.79 – 1.18)
Gearshift lever height 60 – 70
----
(2.36 – 2.76)

–6–
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM STANDARD/SPECIFICATION NOTE
Thermostat valve opening
Approx. 82 °C (180 °F) ----
temperature
Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) ----
ECT sensor resistance 20 °C
Approx. 2.45 kΩ ----
(68 °F)
50 °C
Approx. 0.811 kΩ ----
(122 °F)
80 °C
Approx. 0.318 kΩ ----
(176 °F)
110 °C
Approx. 0.142 kΩ ----
(230 °F)
Radiator cap valve opening 93 – 123 kPa
----
pressure (0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi)
Cooling fan thermo-switch OFF ON Approx. 105 °C (221 °F) ----
operating temperature ON OFF Approx. 100 °C (212 °F) ----
Engine coolant type Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio ----
of 50:50.
Engine coolant Reserve Approx. 250 ml
----
tank side (0.3/0.2 US/lmp qt)
Engine Approx. 2 150 ml
----
side (2.3 – 1.9 US/lmp qt)

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/lmp qt)/30 sec.
Fuel pressure regulator operating
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
set pressure

–7–
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 k Ω
CMP sensor peak voltage When
0.5 V and more
cranking
CKP sensor resistance 70 – 220 Ω
CKP sensor peak voltage When
0.5 V and more
cranking
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 2.6 V at 760 mmHg (100 kPa)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage Normal 0.4 – 1.4 V
When
Leaning 3.7 – 4.4 V
leaning 65 °
GP switch voltage From 1st to
0.6 V and more
Top
Injector voltage Battery voltage
Ignition coil primary peak voltage When
80 V
cranking
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 0.5 kΩ
Opened Approx. 3.9 kΩ
STP sensor output voltage Closed Approx. 0.5 V
Opened Approx. 3.7 V
STV actuator resistance Approx. 6.5 Ω
EXCVA position sensor
4.5 – 5.5 V
input voltage
EXCVA position sensor At
resistance Approx. 3.1 kΩ adjustment
position
EXCVA position sensor Closed 0.5 – 1.3 V
output voltage Opened 3.7 – 4.5 V

–8–
THROTTLE BODY
ITEM SPECIFICATION
Bore size 42 mm
I.D. No. 40F5 (For E-33), 40F4 (For the others)
Idle r/min. 1 150 ± 100 r/min.
Fast idle r/min. 2 200 r/min. (After warming up)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Firing order 1.2.4.3
Spark plug NGK: CR9E
Type
DENSO: U27ESR-N
0.7 – 0.8
Gap
(0.028 – 0.031)
Spark performance Over 8 (0.3) at 1 atm.
CKP sensor resistance 70 – 220 Ω
CKP sensor peak voltage 0.5 V and more
Ignition coil resistance Terminal –
Primary 0.8 – 2.5 Ω
Terminal
Plug cap –
Secondary 8 – 18 kΩ
Terminal
Ignition coil primary peak voltage 80 V
Generator coil resistance 0.2 – 0.9 Ω
Generator no-load voltage
65 V (AC) and more at 5 000 r/min.
(when engine is cold)
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3–5Ω
GP switch voltage 0.6 V and more (From 1st to top without neutral)
Battery Type designation FTX12-BS
Capacity 12 V 36 kC (10 Ah)/10 HR
Fuse size HI 10 A (E-02, 19)/15 A (E-03, 24, 28, 33)
Headlight
LO 10 A
Signal 10 A
Ignition 15 A
Fuel 10 A
Fan 10 A
Main 30 A

–9–
WATTAGE Unit: W
STANDARD/SPECIFICATION
ITEM
E-03, -24, -28, -33 Others
Headlight HI 60/55 W ←
LO 55/55 W 55 W
Position/Parking light 5W
Brake light/Taillight LED ←
Turn signal light 18 W × 4 ←
License plate light 5W ←
Combination meter light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
FI indicator light/Oil pressure
indicator light/Engine coolant LED ←
temp. indicator light
Fuel level indicator light LED ←
Engine RPM indicator light LED ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 60 – 70
----
(2.4 – 2.8)
Brake disc thickness 5.3 – 5.7 5.0
Front
(0.209 – 0.224) (0.177)
4.8 – 5.2 4.5
Rear
(0.189 – 0.205) (0.177)
Brake disc runout 0.30
----
(0.012)
Master cylinder bore Front & 14.000 – 14.043
----
Rear (0.5512 – 0.5529)
Master cylinder piston diam 13.957 – 13.984
Front ----
(0.5495 – 0.5506)
13.957 – 13.984
Rear ----
(0.5495 – 0.5506)
Brake caliper cylinder bore * 27.000 – 27.076
Leading ----
(1.0630 – 1.0660)
Front
* 32.030 – 32.106
Trailing ----
(1.2610 – 1.2640)
38.180 – 38.230
Rear ----
(1.5031 – 1.5051)

– 10 –
 ITEM STANDARD LIMIT
Brake caliper piston diam * 26.920 – 26.970
Leading ----
(1.0598 – 1.0618)
Front
* 31.950 – 32.000
Trailing ----
(1.2579 – 1.2598)
38.110 – 38.130
Rear ----
(1.5004 – 1.5012)
Brake fluid type DOT 4 ----
Wheel rim runout 2.0
Axial ----
(0.08)
2.0
Radial ----
(0.08)
Wheel rim size Front 17 M/C × MT 3.50 ----
Rear 17 M/C × MT 6.00 ----
Wheel axle runout 0.25
Front ----
(0.010)
0.25
Rear ----
(0.010)

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure 250 kPa
Front ----
(Solo riding) (2.50 kgf/cm², 36 psi)
290 kPa
Rear ----
(2.90 kgf/cm², 42 psi)
Cold inflation tire pressure 250 kPa
Front ----
(Dual riding) (2.50 kgf/cm², 36 psi)
290 kPa
Rear ----
(2.90 kgf/cm², 42 psi)
Tire size Front 120/70 ZR17 M/C (58 W) ----
Rear 190/50 ZR17 M/C (73 W) ----
Tire type Front BRIDGESTONE: BT011F F ----
Rear BRIDGESTONE: BT012R F ----
Tire tread depth 1.6
Front ----
(Recommended depth) (0.06)
2.0
Rear ----
(0.08)

– 11 –
SUSPENSION Unit: mm (in)
ITEM STANDARD LIMIT
Front fork stroke 120
----
(4.92)
Front fork spring free length 230.0 225
(9.06) (8.86)
Front fork oil level (without spring, 101
----
outer tube fully compressed) (3.98)
Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil ----
Front fork oil capacity (each leg) 509 ml
----
(17.2/17.9 US/Imp oz)
Front fork spring adjuster 4.5 th groove from top ----
Front fork damping force Rebound 6 clicks out from stiffest position ----
adjuster Compression 11 clicks out from stiffest position ----
Rear shock absorber spring 179.6
----
pre-set length (7.07)
Rear shock absorber damping Rebound 8 clicks out from stiffest position ----
force adjuster Compression 8 clicks out from stiffest position ----
Rear wheel travel 130
----
(5.1)
Swingarm pivot shaft runout 0.3
----
(0.01)

– 12 –
FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 90 pump
octane ( R +2 M ).
Gasoline containing MTBE (Methyl Tertiary Butyl
E-03, 28, 33
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
Gasoline used should be graded 95 octane or
Others
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 18 L
reserve (4.8/4.0 US/lmp gal)
Fuel level
Approx. 4.2 L
indicator light
(1.1/0.9 US/lmp gal)
lighting
Engine oil type SAE 10 W/40, API, SF or SG
Engine oil capacity 3.0 L
change
(3.2/2.6 US/lmp qt)
3.3 L
Filter change
(3.5/2.9 US/lmp qt)
3.6 L
Overhaul
(3.8/3.2 US/lmp qt)

– 13 –
PERIODIC MAINTENANCE CHART
Interval miles 600 4 000 7 500 11 000 14 500
km 1 000 6 000 12 000 18 000 24 000
Item months 2 12 24 36 48
Air cleaner element ---- I I R I
Spark plugs ---- I R I R
Valve clearance ---- ---- ---- ---- I
Exhaust valve I ---- I ---- I
Engine oil R R R R R
Engine oil filter R ---- ---- R ----
---- I I I I
Fuel line
Replace fuel hose every 4 years.
Idle speed I I I I I
I
Throttle valve synchronization ---- I ---- I
(E-33 only)
Evaporative emission control system ---- ---- I ---- I
(E-33 only) Replace vapor hose every 4 years.
PAIR (air supply) system ---- ---- I ---- I
Throttle cable play I I I I I
Clutch cable play ---- I I I I
---- I I I I
Radiator hoses
Replace every 4 years.
Engine coolant Replace every 2 years.
Drive chain I I I I I
Clean and lubricate every 1 000 km (600 miles).
Brakes I I I I I
---- I I I I
Brake hoses
Replace every 4 years.
---- I I I I
Brake fluid
Replace every 2 years.
Tires ---- I I I I
Steering I ---- I ---- I
Front forks ---- ---- I ---- I
Rear suspension ---- ---- I ---- I
Exhaust pipe bolts and muffler bolt and nut T ---- T ---- T
Chassis bolts and nuts T T T T T
NOTE:
I=Inspect and clean, adjust, replace or lubricate as necessary;
R=Replace; T=Tighten

– 14 –
FRONT BRAKE
CONSTRUCTION

1 Front brake lever 9 Brake hose

2 Dust boot 0 Brake hose !
3 Piston set A Front master cylinder mount- ITEM N·m kgf-m lb-ft
ing bolt A 10 1.0 7.0
4 Piston seal B Brake hose union bolt B 23 2.3 16.5
5 Dust seal C Caliper mounting bolt C 39 3.9 28.0
6 Brake caliper piston D Caliper air bleeder valve D 8 0.8 6.0
7 Brake pad E Caliper housing bolt E 22 2.2 16.0
8 Brake pad spring F Brake pad mounting pin F 16 1.6 11.5

– 15 –
"
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix
different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake
fluid left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.


Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage then severely.

BRAKE PAD REPLACEMENT

• Loosen the pad mounting pins 1.
• Remove the brake caliper by removing the caliper mounting
bolts 2.
• Remove the pad mounting pins 1, brake pads and spring.

* Do not operate the brake lever while dismounting the
pads.
* Replace the brake pads as a set, otherwise braking
performance will be adversely affected.

NOTE:
* When the caliper is removed, care must be used so as not to
cause stress to the brake hose.
* The spring removal or reinstallation must be made with the pis-
ton in returned position.

• Install the spring.

NOTE:
In installing the spring to the caliper, bring its wider side of pawl
A facing top.

– 16 –
• Install the new brake pads.
• Tighten each bolt to the specified torque.
! Pad mounting pin 1: 16 N·m (1.6 kgf-m, 11.6 lb-ft)
Front brake caliper mounting bolt 2:
39 N·m (3.9 kgf-m, 28.0 lb-ft)
NOTE:
After replacing the brake pads, pump the brake lever a few times
to check for proper brake operation and then check the brake
fluid level.

– 17 –