Rear brake

Tightening torque

@: 30 - 36 N·m

(3.0 - 3.6 kg-m, 21.5 - 26.0 lb-ft)

@: 20 -31 N·m

©: 8 - 12 N·m

(0.8 - 1.2 kg-m, 6.0 - 8.5 lb-ft)

(QJ: 15 - 20 N·m

(1.5 - 2.0 kg-m, 11.0 -14.5 lb-ft)

®: 6 - 9 N-m

(0.6 - 0.9 kg-m, 4.5 - 6.5 lb-ft)

(£): 15 -20 N·m

(1.5 - 2.0 kg-m, 11.0 - 14.5 lb-ft)

• Remove the d ust sea l cover.

• R emove the cl i ps, pi ns a nd spri ngs.

• Remove the pads.

CAUTION:

* Do not operate the brake pedal whi le removing the pads.

* Replace the brake pad as a set, otherwise brak ing perform­ ance will be adversely aff ected.

• Remove the brake hose union bolt and catch the brake fluid in a suitable receptacle.

• Remove the caliper mounting bolts.

• Remove the torque link bolt and nut, and take off the caliper.

NOTE:

Slightly loosen the caliper housing bolts to facilitate later dis­ assembly before removing the caliper mounting bolts.

•

• Remove the caliper housing bolts and separate the caliper halves.

• Remove the 0-ring.

Once separate the caliper halves, replace the 0-ring with a new one.

•

CAUTION:

Do not use high pressure air to prevent piston damage.

•

CALIPER AND DISC INSPECTION

CALIPER _ _...................................... Refer to page 7-7.

PISTON.......................................... Refer to page 7-7.

RUBBER PARTS.............................. Refer to page 7-7. DISC............................................. Refer to page 7-8.

CALIPER REASSEMBLY AND REMOUNTING

Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points:

CAUTION:

* Wash the caliper components with fresh brake fluid before reassembly.

* Never use cleaning solvent or gasoline to wash them.

* Apply brake fluid to the caliper bore and piston to be in­ serted into the bore.

* Bleed air from the brake system after reassembling the caliper.

(Refer to page 2-14.)

CALIPER BOLTS

Tighten each bolt to the specified torque. (Refer to page 7-21.)

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·

• Remove the reservoir tank mounting bolt.

•

NOTE:

Slightly loosen the master cylinder mounting bolts CD before removing the right footrest bracket mounting bolts.

09900-00410: Hexagon wrench set

•

CAUTION:

Immediately and completely wipe off any brake fluid contact­

ing any part of the motorcycle. The fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely.

• Remove the rear brake light switch.

•

• Remove the master cylinder from the right footrest bracket. 09900-00410: Hexagon wrench set

• Remove the reservoir tank hose.

• Remove the reservoir tank cap and drain brake fluid from

the reservoir tank.

•

09900-06105: Snap ring pliers

• Remove the push rod, piston, primary cup and spring.

•

CAUTION:

The removed 0-ring should be replaced with a new one.

MASTER CYLINDER INSPECTION

CYLINDER, PISTON AND CUP SET

Inspect the ·cylinder bore wall for any scratches or other damage.

Inspect the piston surface for any scratches or other damage. Inspect the cup set and each rubber part for damage.

MASTER CYLINDER REASSEMBLY AND REMOUNTI NG

CAUTION:

Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore.

CAUTION:

Bleed air from the brake system after reassembling master cylinder. (Refer to page 2-14.)

Adjust the rear brake light switch and brake pedal height after installation. (Refer to page 2-14.)

•

Brake hose union bolt CD: 15 - 20 N-m

(1.5 - 2.0 kg-m, 11.0 - 14.5 lb-ft)

Master cylinder mounting 8 - 12 N-m

bolt ®: (0.8 - 1.2 kg-m, 6.0 - 8.5 lb-ft)

R ight footrest mounting bolt ®:

18 - 28 N-m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

REAR WHEEL

Th1360: Apply THR EAD LOCK SUPER " 1360".

G: Apply SUPER GR EASE " A".

CD Cotter pin (For E-03, 28 and

Tightening torque

@: 18 -28 N-m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

@: 40 -60 N-m

(4.0 - 6.0 kg-m, 29.0 - 43.5 lb-ft)

©: 50 - 80 N-m... Normal nut with

cotter pin

(5.0 - 8.0 kg-m, 36.0 - 58.0 lb-ft)

55 - 88 N·m... Self-lock nut

(5.5 - 8.8 kg-m, 40.0 - 63.5 lb-ft)

• Support the motorcycle with the center stand.

• R emove the rear brake caliper mounting bolts and lower the caliper along with the torque link.

NOTE:

Do not operate the brake pedal while removing the rear wheel.

•

• Remove the rear axle nut.

• Loosen the chain adjusting nuts, left and right.

• Draw out the axle shaft.

•

• Remove the rear wheel.

•

• Remove the five dampers out of the wheel hub.

•

INSPECTION AND DISASSEMBLY

TIRE.............................................. Refer to page 7-33.

WHEEL AND SPROCKET DRUM BEARINGS

Inspect the play of respective bearings by hand while they are in the wheel and sprocket drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual.

• Drive out the wheel bearings and sprocket drum bearing by using an appropriate tool.

CAUTION:

The removed bearings should be replaced with new ones.

AXLE SHAFT

Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.

09900-20606: Dial gauge (1/100) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)

Service limit: 0.25 mm (0.010 in)

WHEEL

Make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replac­ ing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

Service limit (Axial and Radial): 2.0 mm (0.08 in)

SPROCKET

Inspect the sprocket teeth for wear. If they are worn as illus­ trated, replace the sprocket and drive chain.

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Normal wear Excessive wear

•

• Remove the spacer CD.

Inspect the lip of dust seal for damage.

CAUTION:

The removed dust seal should be replaced with a new one.

Inspect the dampers for wear and damage.

Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points:

WHEEL BEARING

• Apply grease to the bearings before installing.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GREASE " A"

99000-25010: SUZUKI SUPER GREASE " A"

• Install the wheel bearings by using the special tools. 09924-84510: Bearing installer set

NOTE:

First install the right wheel bearing, then install the left wheel bearing. The sealed cover on the bearing is positioned outside. Refer to next page.

Spacer

SPROCKET DRUM BEARING AND SPROCKET

• Install the bearing by using the special tool. 09913-75520: Bearing installer

• Apply grease to the bearing and oil seal lip.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GREASE " A"

{For the other models)

99000-25010: SUZUKI SUPER GREASE " A"

Lef t bea ri ng

Clea ra nce

Lef t side

R ight side

• Tighten the sprocket mounting nuts to the specified torque.

Tightening torque: 40 - 60 N-m

(4.0 - 6.0 kg-m, 29.0 - 43.5 lb-ft)

• Make sure that the brake disc is clean and free of any greasy matter.

• Apply THR EAD LOCK SUPER " 1360" to the disc bolts and

tghten them to the specified torque.

99000-32130: THREAD LOCK SUPER " 1360"

Tightening torque: 18 - 28 N-m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

TIGHTENING TORQUE

Axle nut:

50 - 80 N-m (5.0 - 8.0 kg-m, 36.0 - 58.0 lb-ft)... Normal nut with cotter pin 55 - 88 N-m (5.5 - 8.8 kg-m, 40.0 - 63.5 lb-ft)... Self-lock nut

Brake caliper mounting bolt:

21 - 31 N-m (2.1 - 3.1 kg-m, 14.5 - 22.5 lb-ft)

ADJUSTMENT

• Adjust the chain slack after rear wheel installation. (Page

2-11.)