Suzki Burgman AN400. Manual - part 55

CHASSIS     7-23

WHEEL BEARING

• Apply SUZUKI SUPER GREASE to the new wheel bearings.

'

99000-25010: SUZUKI SUPER GREASE “A” (Others)
99000-25030: SUZUKI SUPER GREASE “A” (USA)

• Using the special tool, press-fit the left bearing.
• Fit the spacer and press-fit the right bearing.

%

09924-84521: Bearing installer set

$

* Position the sealed side of bearing facing outside.
* Use care not to allow the spacer to skew.

Left

Right

Left

Right

spacer

clearance

7-24     CHASSIS

BRAKE DISC

• Apply THREAD LOCK to the brake disc bolts and tighten

them to the specified torque.

(

99000-32130: THREAD LOCK SUPER “1360”

%

Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

)

DUST SEAL

• Press-fit the dust seal 

 

1

 using the special tool.

%

09913-70210: Bearing installer set (35 mm)

SPACER

• Install the spacer 

 

1

.

• Apply SUZUKI SUPER GREASE to the dust seal lip.

'

99000-25010: SUZUKI SUPER GREASE “A” (Others)
99000-25030: SUZUKI SUPER GREASE “A” (USA)

WHEEL

• Apply SUZUKI SUPER GREASE to the convex parts of

wheel.

'

99000-25010: SUZUKI SUPER GREASE “A” (Others)
99000-25030: SUZUKI SUPER GREASE “A” (USA)

• With the recesses on the wheel engaged with the drive lugs

on the speed sensor, position the wheel to the front fork while
also aligning the speed sensor with the fork stopper.

• Tighten the front axle 

 

1

 to the specified torque.

#

Front axle: 65 N·m (6.5 kgf-m, 47.0 lb-ft)

• Tighten the axle pinch bolt 

 

2

.

#

Axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Keep the brake disc clean, free from dirt and grease.

CHASSIS     7-25

FRONT BRAKE

)

$

1

  Brake hose

2

  Boot

3

  Snap ring

4

  Piston/cup set

5

  Master cylinder

6

  Brake caliper

7

  Dust seal

8

  Piston seal

9

  Piston

0

  Brake pad

A

  Pad spring

A

  Union bolt

B

  Caliper housing bolt

C

  Caliper mounting bolt

ITEM

     N·m           kgf-m           Ib-ft

A

     23

          2.3             16.5

B

     23

          2.3             16.5

C

     25

          2.5             18.0

* 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 severly.

7-26     CHASSIS

BRAKE FULID REPLACEMENT (

!

2-17)

BRAKE FULID AIR BLEEDING (

!

2-19)

BRAKE PAD REPLACEMENT

• Remove the front brake pad pin 

 

1

.

• Remove the front brake pads.
• Remove the combination brake pad pin 

 

2

.

• Remove the combination brake pads.

#

Pad pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

$

• Reassemble the brake pad in the reverse order of disassem-

bly.

• Pay attention to the following points:
• 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.

CALIPER REMOVAL AND DISASSEMBLY

• Drain brake fluid of both the front brake side and the combina-

tion brake side. (

!

2-18)

$

• Remove the union bolts 

 

1

 and caliper mounting bolts 

 

2

.

• Remove the brake pad. (

!

7-26)

• Remove the caliper housing bolts 

 

3

.

NOTE:
Slightly loosen the caliper housing bolts 

 

3

 before removing the

caliper mounting bolts to facilitate later disassembly.

* Do not operate the brake lever while removing the

brake pads.

* Replace the brake pads as a set, otherwise braking

performance will be adversely affected.

To prevent brake fluid from splashing on the parts
nearby, cover the parts with cloth.