Air SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

BRAKES 5-9
EXCESSIVE PEDAL TRAVEL INSPECTION
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30 kg (66
lbs) load, measure brake pedal to wall (dash panel silencer)
clearance “a”.
If clearance “a” is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or
air is in lines.
Should clearance “a” remain less than specification even
after replacement of brake shoes and bleeding of system,
other possible but infrequent cause is malfunction of rear
brake shoe adjusters or booster push rod length out of
adjustment.
–Bleed brake system. Refer to “AIR BLEEDING OF BRAKE
SYSTEM”.
–Remove brake drums for adjuster inspection. (Refer to
“REAR BRAKE”.) If defective, correct or replace.
Clearance “a” between brake pedal and dash panel
silencer
LH steering vehicle : over 135 mm (5.32 in.)
RH steering vehicle : over 140 mm (5.52 in.)
FRONT BRAKE PAD INSPECTION
Inspect pad linings (1) periodically according to maintenance
schedule whenever wheels are removed (for tire rotation or other
reason). Take a look through each end (or hole) of caliper and
check lining thickness of outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less than limit, all
pads must be replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Standard : 10 mm (0.40 in.)
Limit : 2 mm (0.08 in.)
BRAKE DISC INSPECTION
Refer to “BRAKE DISC” for inspection point and procedure.
“a”

5-10 BRAKES
PARKING BRAKE INSPECTION AND
ADJUSTMENT
INSPECTION
Hold center of parking brake lever grip and pull it up with 200 N
(20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches. There should be 4 to 9 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that
ratchet makes while pulling parking brake lever without pressing
its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable referring
to adjustment procedure so as to obtain specified parking brake
store.
ADJUSTMENT
After confirming that above conditions are all satisfied, adjust
parking brake lever stoke by loosening or tightening adjust nut
(1).NOTE:
Check tooth tip of each notch for damage or wear.
If any damage or wear is found, replace parking brake
lever.
NOTE:
Make sure for the following conditions before cable
adjustment.
No air is trapped in brake system.
Brake pedal travel is proper.
Brake pedal has been depressed a few times with
about 100 N (10 kg, 22 lbs) load.
Parking brake lever is pulled up a few times with about
500 N (50 kg, 110 lbs) load.
Rear brake shoes are not worn beyond limit, and self
adjusting mechanism operates properly.
If parking brake lever stroke is less than specification,
loosen adjusting nut (1) as far as end of bolt. Then
depress brake pedal repeatedly with about 300 N (30
kg, 66 lbs) load until adjuster actuator clicking sound
can not be heard from drum brake.
NOTE:
Check brake drum for dragging after adjustment.

BRAKES 5-11
Parking brake stroke (When lever is pulled up at 200 N (20
kg, 44 lbs)
: 4 to 9 notches
BOOSTER OPERATION INSPECTION
There are two ways to perform this inspection, with and without a
tester. Ordinarily, it is possible to roughly determine its condition
without using a tester.
CHECK AIR TIGHTNESS
1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same load as in
ordinary braking and observe pedal travel. If pedal goes
down deep the first time but its travel decreases as it is
depressed the second and more times, air tightness is
obtained.
4) If pedal travel doesn’t change, air tightness isn’t obtained.
CHECK OPERATION
1) With engine stopped, depress brake pedal several times
with the same load and make sure that pedal travel doesn’t
change. NOTE:
For this check, make sure that no air is in hydraulic line.
1. 1st
2. 2nd
3. 3rd
NOTE:
If defective, inspect vacuum lines and sealing parts, and
replace any faulty part.When this has been done, repeat
the entire test.
1. 1st, 2nd, 3rd

5-12 BRAKES
2) Start engine while depressing brake pedal. If pedal travel
increases a little, operation is satisfactory. But no change in
pedal travel indicates malfunction.
CHECK AIR TIGHTNESS UNDER LOAD
1) With engine running, depress brake pedal. Then stop engine
while holding brake pedal depressed.
2) Hold brake pedal depressed for 30 seconds. If pedal height
does not change, condition is good. But it isn’t if pedal rises.
FLUID PRESSURE TEST (IF EQUIPPED WITH
LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
H: Hold
H: Hold
T: 30 seconds

BRAKES 5-13
1) Stop vehicle on level floor and place approximately about
1,000 N (100 kg, 220 lbs) weight (1) on rear housing so that
rear axle weighs 4,500 N (450 kg, 992 lbs).
Rear axle weight
“L” : 4,500 N (450 kg, 992 lbs)
2) Install special tool to front and rear brake.
For front wheel
Special tool
(A) : 09956-02310
(C) : 55473-82030 (Air bleeder plug as a spare part)
For rear wheel
Special tool
(A) : 09956-02310
(C) : 55473-82030 (Air bleeder plug as a spare part)
(D) : 09952-48320
3) Depress brake pedal gradually till fluid pressure of front
brake becomes as specified below and check corresponding
pressure of rear brake then. It should be within specification
given below.
LSPV specification
4) As done above, apply 100 kg/cm
2 pressure to front brake
and check that rear brake pressure then is within specifica-
tion as given below.
LSPV specification (apply 100 kg/cm
2 pressure to front
brake) NOTE:
Pressure gauge should be connected to bleeder plug
hole of front (left side brake) and rear (right side brake).
After testing front left side and rear right side, test front
right side and rear left side in the same way.
Front brake Rear brake
7,500 kPa
75 kg/cm
2
1,067 psi4,700 – 6,900 kPa
47 – 69 kg/cm
2
669 – 981 psi
Front brake Rear brake
10,000 kPa
100 kg/cm
2
1,422 psi5,400 – 7,700 kPa
54 – 77 kg/cm
2
768 – 1,094 psi

BRAKES 5-15
BRAKE HOSE AND PIPE INSPECTION
HOSE
The brake hose assembly should be checked for road hazard
damage, for cracks and chafing of outer cover, for leaks and blis-
ters. A light and mirror may be needed for an adequate inspec-
tion. If any of above conditions are observed on brake hose, it is
necessary to replace it.
PIPE
Inspect the pipe for damage, cracks, dents and corrosion. If any
defect is found, replace it.
ON-VEHICLE SERVICE
AIR BLEEDING OF BRAKE SYSTEM
Bleeding operation is necessary to remove air whenever it
entered hydraulic brake system.
Hydraulic lines of brake system are based on the diagonal split
system. When a brake pipe or hose was disconnected at the
wheel, bleeding operation must be performed at both ends of the
line of the removed pipe or hose. When any joint part of the mas-
ter cylinder of other joint part between the master cylinder and
each brake (wheel) was removed, the hydraulic brake system
must be bled at all 4 wheel brakes.
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
NOTE:
Perform bleeding operation starting with wheel cylinder
farthest from master cylinder and then at front caliper of
the same brake line. Do the same on the other brake line.
1. Right brake caliper 4. Left wheel cylinder
2. Left brake caliper A : FRONT
3. Right wheel cylinder B : REAR

5-16 BRAKES
1) Fill master cylinder reservoir with brake fluid and keep at
least one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap.
Attach a vinyl tube (1) to bleeder plug, and insert the other
end into container (2).
3) Depress brake pedal several times, and then while holding it
depressed, loosen bleeder plug about one-third to one-half
turn.
4) When fluid pressure in cylinder is almost depleted, retighten
bleeder plug.
5) Repeat this operation until there are no more air bubbles in
hydraulic line.
6) When bubbles stop, depress and hold brake pedal and
tighten bleeder plug.
Tightening torque
Front bleeder plug : 11.0 N·m (1.1 kg-m, 8.0 lb-ft)
Rear bleeder plug : 8.0 N·m (0.8 kg-m, 6.0 lb-ft)
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to
pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level.
10) Check brake pedal for sponginess. If found spongy, repeat
entire procedure of bleeding.
MAX
MIN
MAX
MIN

5-20 BRAKES
DISASSEMBLY
1) Remove piston with air blown into flexible hose bolt installa-
tion hole.
2) Remove cylinder boot (1).
3) Remove piston seal using a thin blade like a thickness
gauge, etc.
4) Remove bleeder plug and cap from caliper.
INSPECTION
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace.CAUTION:
Clean around caliper with brake fluid before disassem-
bly.
WARNING:
Do not apply too highly compressed air which will cause
piston to jump out of cylinder. Place a cloth (1) to prevent
piston from damage. It should be taken out gradually
with moderately compressed air. Do not place your fin-
gers in front of piston when using compressed air.
CAUTION:
Use care not to cause damage to cylinder boot.
1
CAUTION:
Be careful not to damage inside (bore side) of cylinder.

BRAKES 5-21
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth
return of piston.
In such case, replace rubber seal.
ASSEMBLY
Assemble parts in reverse order of disassembly, observing the
following instructions.
“A” : Grease 99000-25010
Install piston seal to caliper referring to the following instruc-
tions.
a) Replace with a new one at every overhaul. Fit piston seal
(1) into groove in cylinder taking care not to twist it.
CAUTION:
Wash each part cleanly before installation in the same
fluid as the one used in master cylinder reservoir.
Never use other fluid or thinner.
Before installing piston and piston seal to cylinder,
apply fluid to them.
After reassembling brake lines, bleed air from them.
Install a new piston seal into groove in cylinder
securely making sure that it is not twisted.
Before installing caliper to carrier, install slide pin with
grease applied into caliper carrier hole and check for
its smooth movement in thrust direction.
1

BRAKES 5-23
4) Torque flexible hose joint bolt to specification.
Tightening torque
Flexible hose joint bolt (b) : 23 N·m (2.3 kg-m, 17.0 Ib-ft)
5) Install E-ring to strut securely.
6) Lower hoist.
7) Torque wheel nuts to specifications.
Tightening torque
Wheel nuts : 85 N·m (8.5 kg-m, 61.5 Ib-ft)
8) After completing installation, fill reservoir with brake fluid and
bleed air from brake system. Perform brake test and check
each installed part for oil leakage.
BRAKE DISC
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper carrier bolts
(2 pcs)
3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).WARNING:
Make sure that flexible hose is not twisted when tighten-
ing joint bolt. If it is twisted, reconnect it using care not to
twist it.
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
NOTE:
Hang removed caliper with a wire hook or the like so as
to prevent brake hose from bending and twisting exces-
sively or being pulled.
Don’t operate brake pedal with brake pads removed.