Brake Caliper - Suzuki Intruder 1978 Service Manual

Installation (See Figure 3 - 124.)
1. Install the chaincase and brake disc onto the
jackshaft as an assembly. Be sure to properly
align the woodruff key between the jacksha ft
and the brake hub prior to installation . Torque
the nuts 18 ft Ib (2.5 kg -m).
2. Install the upper sprocket spacer.
3. Install the upper sprocket, lower sprocket, (lip
on the lower sprocket goes toward the bearing)
and the chain as a unit. Install the lowe r
sprocket bolt and washer, torque 35 ft Ib (4.84
kg-m). Install the upper sprocket bolt and
washer, torque 40 to 50 ft Ib (5.53-6.92 kg -m).
4. Install the chain guides, tens ioner spr ing and
hair pin retainers.
5. Insta ll brake cable and return spr ing.
6. Attach radiator bracket and reinstall the
ri1 uffler .
7. Instal l the chaincase cover and new O-ring
seal. Fill the cha incase with DEXRON II auto -
matic transmission fluid to the center of the
sight gauge. Reinstall the fill plug .
8. Adjust track tension. Refer to Section 2.
Brake Caliper
Remova l (See Figure 3-125.)
1. Remove brake return spring . Remove brake
cable from clevis retainer. Remove brake cable
from brake cable bracket.
2. Remove nut, washer, brake lever, spring and
guide, and push pins from casting.
3. Remove the two bolts and nuts securing the
brake caliper and bracket to the chaincase
casting .
4. Slide brake disc towards center of chassis and
remove the
movable brake pad and back -up
plate.
3-82 BRAKE CALIPER
Repair
Inspect the brake pads for wear. If pad A is worn
so only 1/ 32 in. (0.79 mm) protrudes from t he
cal iper, replace pad
A.
Use contact cement to
secure the new pad. If pad B is worn to 1/ 4 in.
(6.3 mm), replace pad B. (See Figure 3- 126.)
Clean all parts insolvent . Be sure to keep oi l and
grease from the pads. Braki ng action will be im -
paired by oily or greasy pads .
1. Return Spring
2. Clevis Retai ner
3. Brake Cable
4. Brake Cable Bracket
5. Bolts and Nuts
6. Brake Lever
7. Nut
Figure 3-125
Assembly
Apply coat ing of NEVER -SEEZ to push pins. As -
semb le and insta l l brake caliper in the reverse
order of removal and disassembly. Then adjust
brake as instructed in Section 2.
...J'