FRONT BRAKE

CHASSIS 8-65

*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.

BRAKE PAD REPLACEMENT

*When the brake caliper is removed, care must be used so as not to cause stress to the brake hose. (Hang the brake caliper on the frame with a string, etc.)

*When removing the pad spring, push the piston all the way into the brake caliper.

•Inspect the pad mounting pins for bent or damage. If any defects are found, replace the pad mounting pins with the new ones.

Specification and classification: DOT 4

Bleed air from the brake system. ( 2-23)

CHASSIS 8-67

CALIPER REMOVAL

•Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta-

cle.

NOTE:

Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid.

• Remove the brake pads and spring. ( 8-65)

Never reuse the brake fluid left over from previous servicing and stored for long periods of time.

Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage.

• Remove the O-ring 3.

Replace the O-ring with a new one.

•Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air.

Avoid using high pressure air to prevent piston damage.

8-68 CHASSIS

• Remove the dust seals 4 and piston seals 5.

Avoid reusing the dust seals and piston seals to prevent fluid leakage.

CALIPER INSPECTION

BRAKE CALIPER

• Inspect the brake caliper cylinder wall for nicks, scratches or

*Clean the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them.

*Do not wipe the brake fluid off after cleaning the components.

*When cleaning the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or others.

*Replace the piston seals and dust seals with the new ones when reassembly. Apply the brake fluid to both seals when installing them.

CHASSIS 8-69

PISTON SEAL

• Install the piston seals as shown in the illustration.

Dust seal

Caliper body

Piston seal

O-RING

• Install the new O-ring 1 and reassemble caliper halves.

Replace the O-ring with a new one.

CALIPER INSTALLATION

Install the caliper in the reverse order of removal. Pay attention to the following points:

•Install the spring and brake pads. ( 8-66)

•Install the brake caliper. ( 8-66)

•Tighten each bolt to the specified torque.

Front brake hose union bolt:

23 N·m (2.3 kgf-m, 16.5 lb-ft)

*The seal washers should be replaced with the new ones to prevent fluid leakage.

*Bleed air from the system after reassembling the caliper. ( 2-23)

8-70 CHASSIS

BRAKE DISC INSPECTION

•Visually check the brake disc for damage or cracks.

•Measure the thickness with a micrometer.

•Replace the disc if the thickness is less than the service limit or if damage is found.

Front disc thickness: Service Limit: 5.0 mm (0.20 in)

09900-20205: Micrometer (0 – 25 mm)

•Remove the brake calipers. ( 8-65)

•Measure the runout with a dial gauge.

•Replace the disc if the runout exceeds the service limit.

Front disc runout: Service Limit: 0.30 mm (0.012 in)

09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

*Brake disc removal ( 8-11)

*Brake disc installation ( 8-14)

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CHASSIS 8-71

MASTER CYLINDER REMOVAL AND

DISASSEMBLY

•Drain the brake fluid. ( 8-66)

•Disconnect the front brake light switch lead wires 1.

•Place a rag underneath the union bolt 2 on the master cylinder to catch any split brake fluid. Remove the union bolt and

disconnect the brake hose.

Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely.

• Remove the master cylinder by removing the master cylinder

• Remove the brake switch 7 and brake lever 8.

8-72 CHASSIS

• Remove the dust boot 9 push rod 0 and snap ring A.

• Remove the following parts.

B Secondary cup C Piston

D Primary cup E Return spring

F Return spring guide G Air bleeder valve

• Remove the connector J and O-ring K.

MASTER CYLINDER INSPECTION

•Inspect the master cylinder bore for any scratches or other damage.

CHASSIS 8-73

•Inspect the piston surface for any scratches or other damage.

•Inspect the primary cup, secondary cup and dust seal for

wear or damage.

MASTER CYLINDER REASSEMBLY

Reassemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

• Apply SUZUKI SILICONE GREASE to the push rod.

99500-25100: SUZUKI SILICONE GREASE

8-74 CHASSIS

• Apply SUZUKI SILICONE GREASE to the brake lever pivot bolt.

99000-25100: SUZUKI SILICONE GREASE

Brake lever pivot bolt: 1 N·m (0.1 kgf-m, 0.7 lb-ft) Brake lever lock-nut: 6 N·m (0.6 kgf-m, 4.5 lb-ft)

Clearance

• Tighten the union bolt. (Brake hose routing: 10-24)

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

*The seal washers should be replaced with the new ones to prevent fluid leakage.

*Bleed air from the system after reassembling the master cylinder. ( 2-23)