Suzuki Burgman 400 - Service manual > Front Brake Caliper Parts Inspection

Refer to "Front Brake Caliper Disassembly and Assembly ".

Inspect the following parts.

Brake Caliper Cylinder

Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one.

Brake Caliper Piston

Inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, replace the piston with a new one.

Front Brake Disc Removal and Installation

Removal

1) Remove the front wheel assembly. Refer to "Front Wheel Assembly Removal and Installation".

2) Remove the front brake disc.

Installation

Install the front brake disc in the reverse order of removal. Pay attention to the following points:

• Make sure that the brake discs are clean and free of any grease.
• Apply thread lock to the brake disc bolts and tighten them to the specified torque.

: Thread lock cement 99000-32130 (Thread Lock Cement Super 1360 or equivalent)

Tightening torque
Brake disc bolt (a): 23 N*m (2.3 kgf-m, 16.5 lb-ft)

Front Brake Disc Inspection

Brake Disc Thickness

Check the brake disc for damage or cracks and measure the thickness using the micrometer.

Replace the brake disc if the thickness is less than the service limit or if defect is found.

Special tool (A): 09900-20205 (Micrometer (0 - 25 mm) )

Brake disc thickness
Service limit (Front): 4.0 mm (0.16 in)

Brake Disc Runout

1) Remove the front brake caliper. Refer to "Front Brake Caliper Removal and Installation ".

2) Measure the runout using the dial gauge.

Replace the disc if the runout exceeds the service limit.

Special tool
(A): 09900-20607 (Dial gauge (1/100 mm, 10 mm) )
: 09900-20701 (Magnetic stand)

Brake disc runout
Service limit: 0.30 mm (0.012 in)

3) Install the front brake caliper. Refer to "Front Brake Caliper Removal and Installation".

Specifications

Service Data

Brake + Wheel

Unit: mm (in)

Tightening Torque Specifications

NOTE The specified tightening torque is also described in the following.

Reference: For the tightening torque of fastener not specified in this section, refer to "Tightening Torque Specifications".

Special Tools and Equipment

Recommended Service Material

NOTE Required service material is also described in the following.

Special Tool

09900-20205 Micrometer (0 - 25 mm)

09900-20701 Magnetic stand

09900-20607 Dial gauge (1/100 mm, 10 mm)

See also: