Suzki Burgman AN400. Manual - part 57

CHASSIS     7-31

MASTER CYLINDER REASSEMBLY AND 
REMOUNTING

• Reassemble and remount the master cylinder in the reverse

order of disassembly and removal.

• Pay attention to the following points:

$

• For assembly of the piston/cup set, refer to the right illustra-

tion.

 

1

 Boot

 

2

 Spring

 

3

 Primary cup

 

4

 Piston

 

5

 Secondary cup

 

6

 Snap ring

• With the convex part 

 

A

 of brake light switch with the hole 

 

B

of master cylinder, assemble the brake light switch.

• When remounting the brake master cylinder onto the  handle-

bars, align the master cylinder holder’s mating surface with
punch mark 

 

C

 on the handlebars.

• Tighten the upper bolt first temporarily to provide clearance

on the lower side and then tighten both the bolts to the speci-
fication.

#

Master cylinder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

* Wash each component with fresh brake fluid before

reassembly. Do not wipe off brake fluid after washing
the components.

* Replace the cup set (piston, primary cup, secondary

cup and spring) with a new one with brake fluid
applied.

7-32     CHASSIS

• Install the brake hose and tighten the union bolt 

 

1

. (

!

9-23)

#

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

• Fill the system with brake fluid and bleed air. (

!

2-19)

• Perform the front brake inspection after assembly has been

completed. (

!

2-16)

CHASSIS     7-33

HANDLEBARS

REMOVAL

• Remove the handle cover. (

!

7-11)

• Remove the rear view mirror 

 

1

.

• Remove the left handlebar switches 

 

2

.

• Disconnect the brake light switch lead wires 

 

3

 and remove

the master cylinder 

 

4

. (

!

7-60)

• Remove the handlebar balancer 

 

5

 and grip 

 

6

.

• Remove the rear view mirror 

 

7

.

• Remove the right handlebar switches 

 

8

.

• Disconnect the brake light switch lead wires 

 

9

 and remove

the master cylinder 

 

0

. (

!

7-29)

• Remove the handlebar balancer 

 

A

 and grip 

 

B

.

• Remove the bolts and remove the handlebar holders 

 

C

.

• Remove the handlebars 

 

D

.

1

  Handleber balancer

2

  Handlebars

3

  Grip

7-34     CHASSIS

REASSEMBLY

• Reassemble the handlebars in the reverse order of removal.
• Pay attention to the following points:
• Align the mating surface of handlebar holder with punch mark

 

A

 on the handlebars.

• Apply THREAD LOCK to the handlebar clamp bolts.
• Tighten the forward handlebar clamp bolts first temporarily to

provide clearance on the rear side and then tighten both the
bolts to the specification.

+

99000-32030: THREAD LOCK SUPER “1303”

#

Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• With the stopper 

 

B

 engaged with the handlebar hole 

 

C

,

assemble the handlebar switch.

• When remounting the brake master cylinder onto the handle-

bars, align the master cylinder holder’s mating surface with
punch mark 

 

D

 on the handlebars.

• Tighten the upper bolt first temporarily to provide clearance

on the lower side and then tighten both the bolts to the speci-
fication.

#

Master cylinder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Perform the following inspections after assembly has been

completed.

* Brake  (

!

2-16)

* Throttle operation and cable play (

!

2-12)

Forward

Clearance