Suzuki Burgman 400 - Service manual > Repair Instructions

Rear Brake Components

1. Lock-nut
2. Arm
3. Adjuster
4. Brake-lock shaft
5. O-ring
6. Brake-lock housing bolt
7. Brake-lock housing
8. Gasket
9. Pad spring
10. Air bleeder valve
11. Boot
12. Bracket
13. Pad mounting pin
14. Piston (Upper side)
15. Dust seal
16. Piston seal
17. Piston (Lower side)
18. Piston set
19. Dust seal
20. Piston seal
21. Back plate
22. Shim
23. Brake pad

1. : 22 N*m (2.2 kgf-m, 16.0 lb-ft)
2. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)
3. : 18 N*m (1.8 kgf-m, 13.0 lb-ft)
4. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)

: Apply silicone grease to sliding surface.

: Apply thread lock to thread part.

: Apply brake fluid.

: Do not reuse.

Rear 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 "Rear Brake Pad Replacement".

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

Rear Brake Pad Replacement

Replace the rear brake pad in the following procedures:

! CAUTION Do not operate the brake lever and brake-lock lever while dismounting the caliper.

Refer to "Rear Brake Components".

1) Remove the caliper mounting bolts (1).

2) Remove the pad pins (2) and brake pads (3).

3) Clean up the caliper especially around the pistons.

4) With the caliper piston (front side) pushed back into the caliper, force the other caliper piston (rear side) also into the caliper by turning it clockwise.

! CAUTION When pushing on the caliper piston (rear side), keep holding the caliper piston (front side) securely to prevent it from coming out.

5) Assemble the new pads (4), shims (5) and back plates (6).

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

6) Locate the projection "A" of the brake pad to the center of caliper piston groove.

NOTE Make sure that the projection of the pad is seated onto the retainer on the caliper bracket.

7) Tighten the pad mounting pins (7) to the specified torque.

Tightening torque
Pad mounting pin (a): 18 N*m (1.8 kgf-m, 13.0 lb-ft)

8) Tighten the caliper mounting bolts (8) to the specified torque.

Tightening torque
Caliper mounting bolt (b): 23 N*m (2.3 kgf-m, 16.5 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.

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