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Hi, Brad I would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
3. Brake Rotors---BUZZ
4. Rear Chains---RATTLE
5. Cam Chains---CLICKIT
8. Fairing Panels---WHISTLE
9. Fronk Forks---Plunk
11. Head Gasket---HISS
12. Hydraulic Lifters---TAP
15. Rear Chains---RATTLE
16. Rear Shocks---SQUEAK
18. Shaft Drives---WHIRR
19. Shifting Trans---CLUNK
20. Solid Lifters---TICK
22. Connecting Rods Go---KNOCK-KNOCK---who's there, it's me "*****"
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day. http://www.mtdemocrat.com/roadbeat/suzuki-burgman-400-and-650-a-tale-of-two-cities Suzuki Burgman 400 is running so horrible MPH RPM Reading Suzuki AN400 Service Manual OEM parts for Suzuki http://burgmanriders.com/forums/showthread.php/4043-burgman-400-2004-owners-manual
If present, remove right saddlebag.
Remove the rear master cylinder reservoir cap. As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in. (3.2 mm). You may have to remove fluid to allow for this.
Loosen, but do not remove, both pad pins (12 pt/0.25 in.).
Pry the inside pad back. Use steady pressure to prevent scoring the brake disc. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Once the pistons have been fully retracted into their bores, pull pad pins part way until the inside pads drop free. Note the pad's original orientation for replacement purposes.
Install pad with two tabs on the inboard side of the rear caliper.
Install new inside brake pad using the same orientation as the pad previously removed. Curved portion of pad must face upward.
Install pad pins until the pins snap into place with an audible click. Do not fully tighten at this time.
Pump brake pedal lever to move inside pistons out until they contact inside brake pads.
Pry the outside pad back. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Verify that inside pads are captured between brake disc and pistons. Completely remove pad pins to free outside brake pad. Note the pad's original orientation for replacement purposes.
Install new outside brake pad using the same orientation as the pad previously removed. If the inside pad moved during the previous step, reinstall. Curved portion of pad must face upward.
Install both pad pins through holes in inner and outer
brake pads. Tighten to 180-200 in-lbs (20.3-22.6 Nm).
Hello Dale, this is an easy job on your bike. Use a flat head screw driver and remove the brake pad cover...it will pop off. Remove the hairpin type clips off of the ends of the brake pad pins.... Use pliers & pull the brake pad pins out from the front of the rear brake caliper....Clean the rear brake caliper's piston with brake cleaner. Use a rag and wipe it clean...Reinsert the old brake pads into the caliper. Place a pry bar between the brake pads, then push the inner piston into the caliper body, this will allow room to install new pads.... Remove the old brake pads...Coat the brake pad pins and the new brake pads metal back plates with high-temperature grease.
Slip the new brake pads into the rear brake caliper, then push the brake pad pins halfway into the caliper. Slip the spring clips into place between the brake pads and the brake pad pins. Push the brake pad pins completely through the rear brake caliper. Push the hairpin clips back into the brake pad pin tips. Snap the brake pad cover onto the top of the rear brake caliper....
Pump the rear brake pedal until the pedal feels firm, indicating that the brake pads have closed around the brake rotor...No bleeding will be needed because the system was never opened - That's all there is to it...i hope this information is helpful & good luck with your bike.
For front brake pads replacement you need only usually wrench set, inclusive 7 mm allen key also. But for rear brake pads replacement you need obligatory a special caliper piston pressing tool, in order to press back rear caliper piston with parking brake automatic adjustment!!! For front brake pads. You should buy the brake pads (with wear sensor). For change front brake pads you must raise vehicle, remove wheels, extract the retaining spring of the caliper, and remove the caliper as follow: 1. Do not disconnect the brake hose from the caliper, and do not allow the caliper to hang by the brake hose! 2. Remove top and bottom caps (on back side of the caliper) for access to guide pins, then unbolt and remove them from the brake carrier. Remove the caliper. 3. Now you must thoroughly clean the brake calipers (free of grease). 4. Remove outer brake pad from brake carrier. 5. Pull inner brake pad out of brake caliper piston. 6. Check up the brake fluid level on the reservor, and emptying if neccessary! 7. Push piston back into brake caliper housing. 8. Install inner brake pad (with expanding spring) in brake caliper piston. (Arrow marked on pad - if exist, must point in direction of brake disc rotation when vehicle is moving forward). 9. Install outer brake pad into brake carrier. 10. Bolt brake caliper housing to brake carrier using two guide pins. Tightening torque is 25 Nm. 11. Install both caps. 12. Insert retaining spring into brake caliper housing. Important: Depress the brake pedal firmly several times while the car is stationary so that the brake pads adjust to their normal operating positions!!! Check brake fluid level and top up if neccessary!!!
No, see procedure below listed at autozone.com. Try opening bleeder. You may have a kink somewhere or hose decomposing internally. Else the piston is locked in place. Was the brake working before replacing pads?
Remove 1 / 2 of the volume of brake fluid from the master cylinder to prevent overflow when the caliper piston is compressed.
Raise and safely support the vehicle.
Remove the wheel and tire assemblies.
Remove the brake caliper without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose.
On some disc brake systems it is not necessary to remove the caliper when installing new brake pads. Remove the lower slide bolt and rotate the caliper upward to remove the pads.
Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining.
Use a suitable tool to push the caliper piston into its bore.
Apply a thin coat of grease to the rear face of the brake pad and install the shim. Install the brake pads.
Install the calipers. Lubricate the caliper bolts and boots. If equipped with a 4-cylinder engine, tighten the caliper mounting bolts to 24 ft. lbs. (33 Nm). If equipped with a 6-cylinder engine, tighten the caliper mounting bolts to 54 ft. lbs. (74 Nm).
Install the wheel and tire assemblies and lower the vehicle.
Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid in the master cylinder and add as necessary.
There is no adjustment of calipers - they are hydraulic.
If you mean how do you push back the brake piston to allow you to install new brake pads, why didn't you say so? :)
Use a wooden stick (I use the wife's wooden spoon - but don't get caught!) to push back the pistons - don't use anything metal, you run the risk of damaging the dust seals.
A SIX INCH C-CLAMP, PURCHASED AT THE AUTO PARTS STORE, IS NEEDED TO PUSH THE PISTON INTO THE CALIPER AS LONG AS IT IS THE FRONT BRAKES THAT YOU ARE WORKING ON. IF YOU ARE REFERRING TO THE REAR BRAKES, THEN THE PISTON MUST BE TURNED COUNTERCLOCKWISE(TO THE LEFT). HOPE THIS HELPS. PLEASE KEEP ME POSTED. THANKS FOR USING FIX-YA. GOOD LUCK