Although the thought of replacing the front brake pads on a Suzuki Eiger ATV may seem daunting to an untrained ATV owner, the truth is that the task can be performed with basic tools and common sense. Once you remove the front wheel, you can easily unbolt the brake caliper from the Eiger's frame, allowing for removal and replacement of the worn brake pads. Take your time to prevent losing parts or making mistakes that will take longer to fix.
Things You'll Need
- 14 mm socket
- Breaker bar
- 8 mm socket
- Socket wrench
- 6 mm Allen socket
- Aerosol brake cleaning spray
- Shop towels
- Flat screwdriver
- Replacement brake pads
Loosen the front wheel's lug nuts using a 14 mm socket and a breaker bar for additional leverage. Engage the parking brake and lift the ATV's front wheels off of the ground using a jack. Remove the lug nuts from the front wheel and pull the wheel off of the axle.
Unbolt the front brake caliper's mounting bracket, using an 8 mm socket to remove the pair of bolts that secure the bracket to the ATV. Lift the caliper upwards and slide it off of the front brake rotor.
Remove the pair of brake pad pins from the caliper, using a 6 mm Allen socket to unscrew the pins. Pull the brake pads and the retaining spring clip out of the caliper. Separate the pads from the retaining spring and pull metal shims off of the back of the brake pads. Insert a pair of new brake pads into the retaining spring clip and press the shims onto the back of the pads.
Clean the interior of the brake caliper with an aerosol brake cleaning spray, concentrating around the caliper's inner pistons. Immediately wipe dry with a clean shop towel.
Press the inner pistons into the brake caliper with a large flat screwdriver. Insert the brake pads and retaining spring clip into the caliper. Insert the brake pad pins into the caliper and through the brake pads' mounting holes. Tighten the pins with a 6 mm Allen socket.
Slide the brake caliper over the front brake rotor and align the caliper bracket with the ATV's frame. Insert and tighten the bracket's mounting bolts with an 8 mm socket. Mount the wheel onto the front axle and tighten the lug nuts with a 14 mm socket, alternating between the lug nuts in a criss-cross pattern until they are fully-tightened. Repeat on the opposite side of the ATV.
Prepare the front brake circuit after the brake pads on both sides of the ATV have been replaced. Slowly pump the front brake lever repeatedly to close the brake pads around the brake rotor, rebuilding hydraulic pressure within the brake circuit. Stop once the brake lever offers a firm resistance when it is pulled in.
Tips & Warnings
- Inspect the caliper's inner pistons for damage or corrosion while the brake pads have been removed. If the pistons show signs of scarring, rusting or leaking, have the caliper rebuilt by a qualified Suzuki technician.
- Double check your brake pads before re-installing the caliper onto the ATV. The brake pads must be fully secured by the pad pins to prevent the pads from moving around freely. Loose pads can bind against the brake rotor and lock the front wheel, creating a dangerous loss of control.
- Always prime the brake circuit after replacing the brake pads to restore the brake's hydraulic pressure.
- "The Professional Motorcycle Repair Program"; Professional Career Development Institute; 1995
- "2004 Suzuki LT-F400 Eiger 4WD Service Manual"; Suzuki Motor Corp.; 2004
- Photo Credit brake calipers image by Tom Oliveira from Fotolia.com
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