Suzuki Burgman 400 - Service manual > Repair Instructions

Front Wheel Components

1. Front wheel
2. Spacer
3. Bearing
4. Dust seal
5. Front axle
6. Collar
7. Brake disc
8. Brake disc bolt
9. Tire
10. Air valve
11. Wheel balancer

1. : 65 N*m (6.5 kgf-m, 47.0 lb-ft)
2. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)

: Apply grease.

: Apply thread lock to thread part.

: Do not reuse.

Front Wheel Assembly Construction

1. Front axle
2. Front brake caliper mounting bolt
3. Front brake disc bolt
   1. Clearance

1. : 65 N*m (6.5 kgf-m, 47.0 lb-ft)
2. : 35 N*m (3.5 kgf-m, 25.5 lb-ft)
3. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)

: Apply grease.

: Apply thread lock to thread part.

Front Wheel Assembly Removal and Installation

Removal

1) Support the motorcycle with a jack or a wooden block.

2) Remove the brake calipers. Refer to "Front Brake Caliper Removal and Installation".

! CAUTION Do not operate the brake lever while removing the caliper.

3) Loosen the axle pinch bolt (1) on the right front fork leg.

4) Loosen the front axle (2).

5) Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block.

! CAUTION Do not carry out the work with the motorcycle resting on the side-stand. Do not support the motorcycle with the fuel tank and the radiator. Make sure that the motorcycle is supported securely.

6) Draw out the front axle and remove the front wheel.

NOTE After removing the front wheel, install the calipers temporarily to the original positions.

7) Remove the collar (3).

Installation

1) Install the collar (1) into the left side of the wheel.

2) Install the front wheel with the front axle.

! WARNING The directional arrow on the tire should point to the wheel rotation, when remounting the wheel.

3) Tighten the front axle (2) to the specified torque using the special tool.

Special tool (A): 09900-18710 (Hexagon socket (12 mm) )

Tightening torque
Front axle (a): 65 N*m (6.5 kgf-m, 47.0 lb-ft)

4) Tighten the brake caliper mounting bolts (3) to the specified torque.

Tightening torque
Front brake caliper mounting bolt (b): 35 N*m ( 3.5 kgf-m, 25.5 lb-ft)

WARNING After remounting the brake calipers, pump the brake lever until the pistons push the pad correctly.

5) Move the front fork up and down 4 or 5 times.

6) Tighten the axle pinch bolt (4) on the right front fork leg to the specified torque.

Tightening torque
Front axle pinch bolt (c): 23 N*m (2.3 kgf-m, 16.5 lb-ft)

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