Brake system of motorcycle Suzuki DL650 V-Strom (2004-2011)

Front brake construction
1. Diaphragm; 2. Dust boot; 3. Piston/cup set; 4. Brake hose; 5. Pin; 6. Pad mounting pin; 7. Brake pad spring; 8. Brake pad; 9. Piston seal; 10. Dust seal; 11. Piston; 12. Caliper holder; 13. Caliper; A. Front brake master cylinder mounting bolt;...

Front brake pad replacement
Remove the caliper. Caution! Do not operate the brake lever while removing the caliper. Remove the pin (1). Remove the brake pads by removing the pad mounting pin (2). Clean up the caliper especially around the caliper pistons. Install the outer pad...

Front brake fluid replacement
Place the motorcycle on a level surface and keep the handlebars straight. Remove the brake fluid reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with the new brake fluid. Specification and...

Front brake caliper — removal and disassembly
Drain the brake fluid. ( 7-60 ) Remove the brake pads. ( 7-59 ) Disconnect the brake hoses by removing the brake hose union bolts. Note: Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. Remove the brake...

Front brake caliper — inspection
Brake caliper Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston Inspect the brake caliper piston surface for any scratches and other...

Front brake caliper — reassembly and remounting
Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: Wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal...

Front 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: 4.5 mm (0.18 in) 09900-20205:...

Front master cylinder — removal and disassembly
Remove the rear view mirror and brake lever cover. Drain the brake fluid. ( 7-60 ) Disconnect the front brake switch coupler (1). Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose...

Front master cylinder — inspection
Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage.

Front master cylinder — reassembly and remounting
Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: Caution! Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or...

Rear brake construction
1. Brake hose; 2. Diaphragm; 3. Reservoir tank hose; 4. Piston/cup set; 5. Push rod; 6. Dust boot; 7. Piston seal; 8. Dust seal; 9. Piston; 10. Pad shim; 11. Pad insulator; 12. Brake pad; 13. Brake pad spring; 14. Caliper bracket; 15. Caliper; A....

Rear brake pad replacement
Remove the plug (1). Loosen the pad mounting pin (2). Remove the caliper bracket bolt (3). Caution! Do not operate the brake pedal while dismounting the pads. Replace the brake pads as a set, otherwise braking performance will be adversely affected....

Rear brake fluid replacement
Remove the right frame cover. ( 7-5 ) Remove the brake fluid reservoir cap. Replace the brake fluid in the same manner as the front brake. ( 7-60 ) Specification and Classification: DOT 4 Caution! Bleed air from the brake system. ( 2-25 )

Rear caliper — removal and disassembly
Drain the brake fluid. ( 7-71 ) Remove the brake pads. ( 7-69 ) Place a rag underneath the union bolt to catch any spilt brake fluid. Disconnect the brake hose by removing the brake hose union bolt (1). Caution! Do not reuse the brake fluid left...

Rear caliper — inspection
Brake caliper Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston Inspect the brake caliper piston surface for any scratches and other...

Rear brake disc — inspection
Inspect the rear brake disc in the same manner as the front brake disc. ( 7-65 ) Service limit: Rear disc thickness: 5 mm (0.20 in) Rear disc runout: 0.30 mm (0.012 in) Brake disc removal ( 7-37 ) Brake disc installation ( 7-42 )

Rear 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...

Rear master cylinder — removal and disassembly
Drain the brake fluid. ( 7-71 ) Remove the brake fluid reservoir tank mounting bolt (1). Loosen the lock-nut (2). Remove the master cylinder mounting bolts (3). Place a rag underneath the union bolt on the master cylinder to catch spilled drops of...

Rear master cylinder — inspection
Cylinder, piston and cup set Inspect the cylinder bore wall for any scratches or other damage. Inspect the cup set and each rubber part for damage.

Rear master cylinder — reassembly and remounting
Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: Caution! Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or...