Suzuki GA413, Service Manual

Page: 197 / 1246

BRAKES 5-1
SECTION 5
BRAKES
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by
an authorized SUZUKI dealer. Refer to AIR BAG SYSTEM COMPONENTS AND WIRING
LOCATION VIEW of GENERAL DESCRIPTION in air bag system section in order to confirm
whether you are performing service on or near the air bag system components or wiring.
Please observe all WARNINGS and SERVICE PRECAUTIONS of ON-VEHICLE SERVICE in air
bag system section before performing service on or around the air bag system components
or wiring. Failure to follow WARNINGS could result in unintentional activation of the system
or could render the system inoperative. Either of these two conditions may result in severe
injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned
to the LOCK position and negative cable is disconnected from the battery. Otherwise, the
system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used as specified during reassembly to
assure proper retention of all parts. There is to be no welding as it may result in extensive damage and
weakening of the metal.
When inspecting and servicing vehicle equipped with ABS, be sure to refer to Section 5E first.
CONTENTS
5
GENERAL DESCRIPTION 5- 3 . . . . . . . . . . . . . . .
Front Disc Brake Caliper Assembly 5- 4 . . . . . .
Rear Drum Brake Assembly 5- 5 . . . . . . . . . . . .
Master Cylinder Assembly 5- 6 . . . . . . . . . . . . .
Booster Assembly 5- 7 . . . . . . . . . . . . . . . . . . . . .
B.P. Valve 5- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV Assembly 5- 9 . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS 5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road Testing Brakes 5-10 . . . . . . . . . . . . . . . . . .
Brake Fluid Leaks 5-10 . . . . . . . . . . . . . . . . . . . . .
Substandard or Contaminated
Brake Fluid 5-10 . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Diagnosis Table 5-10 . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT 5-14 . . . . . . . . . . . . .
Brake Pedal Free Height Adjustment 5-14 . . . .
Stop Light Switch Adjustment 5-14 . . . . . . . . . . .
Excessive Pedal Travel Check 5-14 . . . . . . . . . .
Front Brake Disc Check 5-15 . . . . . . . . . . . . . . . .
Front Brake Pad Lining Check 5-15 . . . . . . . . . .
Rear Brake Shoe Check 5-15 . . . . . . . . . . . . . . .
Brake Pedal Play Check 5-16 . . . . . . . . . . . . . . .
Master Cylinder Check 5-16 . . . . . . . . . . . . . . . .
Rear Drum Brake Shoe Adjustment 5-16 . . . . .
Parking Brake Check and
Adjustment 5-16 . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Brake Hydraulic System 5-17 . . . . . . .
Bleeding Brakes 5-18 . . . . . . . . . . . . . . . . . . . . . .
Brake Hose and Pipe Check 5-19 . . . . . . . . . . . .
Brake Fluid Level Check 5-19 . . . . . . . . . . . . . . .
Booster Operation Check 5-20 . . . . . . . . . . . . . .
Fluid Pressure Test 5-22 . . . . . . . . . . . . . . . . . . . .