Pictures: Rear Brake Pads and Lub. for '03 650 Standard - Suzuki Burgman Forum
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post #1 of 14 (permalink) Old 05-03-2008, 05:53 PM Thread Starter
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Pictures: Rear Brake Pads and Lub. for '03 650 Standard

Disclaimer
This is how I do it, and may, or may not be the way Suzuki does this procedure.
This is meant as a simple picture guide to brake Pad, and simple caliper maintaince.
This does not show removal or care of the Pistons, as I have yet, to have the need to remove, or rework them.
As always if you feel you are not qualified, or are unsure, please has this work done by a qualified mechanic. Always refer the the service manual for proper torque specs. on all fasteners.

Health and Safety notice on dust hazard.

Use proper Caliper specific grease
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Last edited by Jim; 10-08-2013 at 05:06 PM.
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post #2 of 14 (permalink) Old 05-03-2008, 06:04 PM Thread Starter
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

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post #3 of 14 (permalink) Old 05-03-2008, 06:26 PM Thread Starter
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

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post #4 of 14 (permalink) Old 05-03-2008, 06:45 PM Thread Starter
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

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post #5 of 14 (permalink) Old 05-03-2008, 07:04 PM Thread Starter
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

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post #6 of 14 (permalink) Old 05-03-2008, 07:12 PM Thread Starter
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

[attachment=0:2ja50a2j]1.JPG[/attachment:2ja50a2j]

I usually need to pump the rear brake a few times to get the brakes back, then I hold it a few seconds, it seems to help. Next check the parking brake operation, if all is well, test time.

On my test ride it took a few times, but I was able to lock the rear on dry asphalt, I couldn't before.

I did not need to bleed the brake line, and the brakes are firm.

Front brakes here
Pictures: Front Brake Pads and Lub. for '03 650 Standard
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post #7 of 14 (permalink) Old 07-01-2009, 12:57 AM
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

On an AN650 '03, removng the rear brake caliper to replace the pads, I can't get the pistons to retract enough to put the new pads in, much less put the caliper back on the bike straddling the disk. Note that the pads had worn down to metal on metal. Does the caliper assembly need to be replaced? Do you think there's something in the piston that isn't working? Any thoughts would be most appreciated. I'm a fool for a ride but I'm a little shy of the road without a back brake. Regards.

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post #8 of 14 (permalink) Old 07-01-2009, 02:13 AM
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

Great tutorial on the how to. My 04 is coming into a rear tire change, Will be inspecting the pads then.

Rob

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post #9 of 14 (permalink) Old 07-01-2009, 05:53 AM Thread Starter
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

Quote:
Originally Posted by sqtrddy
I can't get the pistons to retract enough to put the new pads in, much less put the caliper back on the bike straddling the disk. Note that the pads had worn down to metal on metal. Does the caliper assembly need to be replaced? Do you think there's something in the piston that isn't working?

Any thoughts would be most appreciated.
The rear brake assembly is a different beast, in that one piston is hydraulically operated buy the left brake, and the other piston is mechanically operated by the parking brake.

The hydraulically operated piston is what we are all familiar with and can be pushed back

The piston that is operated by the parking brake has a + on it and with a screwdriver needs to be turned to the right (clockwise)until it stops. Then align with the pin on the new pad Do NOT "push" the piston back, as there are threads inside it. I do not know how many turns it will take because I have yet to replace the rear pads.

Page 9-74 through page 9-90 in the Service Manual explain the process as well as a complete caliper rebuild.

This thread will also help
Burgman 650 - Rear Disc Brake Caliper and Parking Brake

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post #10 of 14 (permalink) Old 07-01-2009, 07:54 AM
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Re: Pictures: Rear Brake Pads and Lub. for '03 650 Standard

Jim excellent information.

I paid to get mine done and was very glad. A good mechanic worked to free the pistons for quite a while. Only cost $68 for the job. My rear brake was not working good enough to hold the bike with the parking brake. The piston was froze and needed to be freed. Brake job was at 18,000 miles. Front was OK.

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