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Suzki Burgman AN400. Manual - part 7

2-18 PERIODIC MAINTENANCE

• Connect a clear hose

to the air bleeder valve and insert the

other end of the hose into a receptacle.

• Loosen the air bleeder valve and pump the brake lever until

the old brake fluid is completely out of the brake system.

• Close the air bleeder valve and disconnect the clear hose. Fill

the reservoir with new brake fluid to the upper end of the
inspection window.

Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)

COMBINATION BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handle-

bar straight.

• Remove the rear brake caliper cover

• Remove the master cylinder reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with new brake fluid.

)

Specification and classification: DOT4

• Connect a clear hose

to the air bleeder valve and insert the

other end of the hose into a receptacle.

• Loosen the air bleeder valve and pump the brake lever until

the old brake fluid is completely out of the brake system.

• Close the air bleeder valve and disconnect the clear hose. Fill

the reservoir with new brake fluid to the upper end of the
inspection window.

• Next, connect a clear hose

to the air bleeder valve on the

rear brake caliper. The rear brake fluid replacement is the
same way as that of the front one.

PERIODIC MAINTENANCE 2-19

AIR BLEEDING THE BRAKE FLUID CIRCUIT

• Air trapped in the fluid circuit acts like a cushion to absorb a

large proportion of the pressure developed by the master cyl-
inder and thus interferes with the full braking performance of
the brake caliper. The presence of air is indicated by “spongi-
ness” of the blake lever and also by lack of braking force.
Considering the danger to which such trapped air exposes the
machine and rider, it is essential that, after remounting the
brake and restoring the brake system to the normal condition,
the brake fluid circuit be purged of air in the following manner:

• Fill up the master cylinder reservoir to the “UPPER” line

Place the reservoir cap to prevent entry of dirt.

• Connect a clear hose

to the air bleeder valve, and insert

the free end of the pipe into a receptacle.

Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)

• Front brake: Bleed the air from the air bleeder valve.
• Squeeze and release the brake lever several times in rapid

succession and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle; this will remove
the tension of the brake lever causing it to touch the handle-
bar grip. Then, close the valve, pump and squeeze the lever,
and open the velve.

• Repeat this process until the fluid flowing into the receptacle

no longer contains air bubbles.

NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system. Make sure that there is always some
fluid visible in the reservoir.

2-20 PERIODIC MAINTENANCE

• Close the bleeder valve, and disconnect the clear hose.
• Fill the reservoir with brake fluid to the “UPPER” line.

AIR BLEEDING FOR THE COMBINATION BRAKE

• The combination brake system air bleeding is the same man-

ner as that of the front brake one.

• Remove the rear brake caliper cover

• Bleed the air from the rear side first and then the front side.

Clear hose for rear brake

Clear hose for front brake

STEERING

• Steering should be adjusted properly for smooth turning of

handlebars and safe running. Overtight steering prevents
smooth turning of the handlebars and too loose steering will
cause poor stability.

Handle brake fluid with care: the fluid reacts chemi-
cally with paint, plastics, rubber materials and so on.

Inspect initially at 1 000 km (600 miles, 1 months) and
every 12 000 km (7 500 miles, 12 months) thereafter.

PERIODIC MAINTENANCE 2-21

• Check that there is no play in the steering stem while grasping

the lower fork tubes by supporting the machine so that the
front wheel is off the ground, with the wheel straight ahead,
and pull forward. If play is found, perform steering bearing
adjustment as described in page 7-46 of this manual.

FRONT FORK

• Inspect the front forks for oil leakage, scoring or scratches on

the outer surface of the inner tubes. Replace any defective
parts, if necessary. (

7-35)

REAR SUSPENSION

• Inspect the rear shock absorber for oil leakage and mounting

rubbers including engine mounting for wear and damage.
Replace any defective parts, if necessary.

REAR SHOCK ABSORBER ADJUSTMENT

• Turn the adjuster handle, adjust the rear shock absorber

spring pre-load.

Rear shock absorber spring pre-load:

Adjustable range : 17 turns (34 clicks)
Standard position : 2-1/2 turns (9clicks) out

from most softest position

Inspect every 12 000 km (7 500 miles, 12 months).

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