Suzuki Burgman 400 - Service manual > Repair Instructions

Front Brake Components

1. Air bleeder valve
2. Pad mounting pin
3. Brake pad spring
4. Piston seal
5. Dust seal
6. Piston
7. Boot
8. Pin bolt
9. Washer
10. Bracket
11. Front brake pad set
12. Front brake disc

1. : 6 N*m (0.6 kgf-m, 4.5 lb-ft)
2. : 18 N*m (1.8 kgf-m, 13.0 lb-ft)
3. : 18 N*m (1.8 kgf-m, 13.0 lb-ft)
4. : 35 N*m (3.5 kgf-m, 25.5 lb-ft)
5. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)

: Apply thread lock to thread part.

: Apply brake fluid.

: Do not reuse.

Front Brake Pad Inspection

The extent of brake pad wear can be checked by observing the grooved limit line "A" on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. Refer to "Front Brake Pad Replacement".

! CAUTION Replace the brake pad as a set, otherwise braking performance will be adversely affected.

Front Brake Pad Replacement

Replace the front brake pads in the following procedures:

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

1) Loosen the front brake pad mounting pins (1).

2) Remove the front brake caliper mounting bolts (2).

3) Remove the front brake caliper.

4) Remove the front brake pad mounting pins.

5) Remove the front brake pads.

6) Disassemble the shims from the front brake pads.

7) Clean up the caliper especially around the caliper piston and the shim.

8) Assemble the new front brake pads and shims.

! CAUTION Replace the brake pads as a set, otherwise braking performance will be adversely affected.

9) Install the front brake pads.

10) Install the front brake pad mounting pins temporarily.

11) Install the front brake caliper.

12) Tighten the front brake caliper mounting bolts (1) to the specified torque.

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

13) Tighten the front brake pad mounting pin (2) to the specified torque.

Tightening torque
Front brake pad mounting pin (b): 18 N*m (1.8 kgf-m, 13.0 lb-ft)

NOTE After replacing the brake pads, pump the brake lever several times in order to operate the brake correctly and then check the brake fluid level.

See also: