Suzuki Burgman 400 - Service manual > Front Brake Caliper Removal and Installation

Removal

1) Drain brake fluid. Refer to "Brake Fluid Replacement".

2) Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.

NOTE

3) Remove the brake caliper by removing the caliper mounting bolts (3).

Front Brakes

4) Remove the front brake pads. Refer to "Front Brake Pad Replacement".

5) Remove the front brake caliper bracket.

Front Brakes

Installation

Install the front brake caliper in the reverse order of removal. Pay attention to the following points:

! CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque
Front brake caliper mounting bolt (a): 35 N*m (3.5 kgf-m, 25.5 lb-ft)
Front brake pad mounting pin (b): 18 N*m (1.8 kgf-m, 13.0 lb-ft)

! CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque
Front brake hose union bolt (c): 23 N*m (2.3 kgf-m, 16.5 lb-ft)

Front Brakes

! WARNING 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.

Front Brake Caliper Disassembly and Assembly

Refer to "Front Brake Caliper Removal and Installation".

Disassembly

1) Remove the front brake pads. Refer to "Front Brake Caliper Removal and Installation".

2) Remove the front brake pad spring.

Front Brakes

3) Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air.

! CAUTION Do not use high pressure air to prevent piston damage.

Front Brakes

4) Remove the dust seals (1) and piston seals (2).

Front Brakes

5) Remove the rubber boots (3) and the front brake caliper air bleeder valve (4).

Front Brakes

6) Remove the pin bolt from the front brake caliper bracket.

Front Brakes

Assembly

Assemble the front brake caliper in the reverse order of disassembly. Pay attention to the following points:

BF: Brake fluid (DOT 4)

! CAUTION

Front Brakes

! CAUTION Replace the piston seals (1) and dust seals (2) with the new ones.

BF: Brake fluid (DOT 4)

Front Brakes

Tightening torque
Pin bolt (a): 18 N*m (1.8 kgf-m, 13.0 lb-ft)

Front Brakes

See also:

 Suzuki Burgman 400 - Service manual > Repair Instructions

Front Brake Components Air bleeder valve Pad mounting pin Brake pad spring Piston seal Dust seal Piston Boot Pin bolt Washer Bracket Front brake pad set Front brake disc : 6 N*m (0.6 kgf-m, 4.5 lb-ft) : 18 N*m (1.8 kgf-m, 13.0 lb-ft) : 18 N*m (1.8 kgf-m, 13.0 lb-ft) : 35 N*m (3.5 kgf-m, 25.5 lb-ft) : 23 N*m (2.3 kgf-m, 16.5 lb-ft)

 Suzuki Burgman 400 - Service manual > Front Brake Caliper Parts Inspection

Refer to "Front Brake Caliper Disassembly and Assembly ". Inspect the following parts. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one.

Maxi Scooters: