2007 SUZUKI SWIFT Oul

Downloaded from www.Manualslib.com manuals search engine 4A-8 Brake Control System and Diagnosis:
Excessive Pedal Travel InspectionS7RS0B4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300 N (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
air in lines. Should clearance “a” remain less than
specification even after bleeding of system, other
possible infrequent cause is booster push rod length
out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
Brake arm pedal to wall clearance “a”
When pedal depressed at 300 N (30 kg, 66 lbs):
over 75 mm (2.95 in.)
Brake Fluid Level InspectionS7RS0B4106004
1) Check master cylinder, reservoir and reservoir hose (if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX and MIN marks on reservoir.
NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning lamp lights sometimes
during driving, replenis h fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

Stop Light Switch AdjustmentS7RS0B4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clea rance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and stop light switch
“a”: 1.2 – 2.2 mm (0.05 – 0.08 in.)
I6RS0C410005-02
I4RS0B410006-01
I4RS0A410007-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-9
Air Bleeding of Brake SystemS7RS0B4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

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 master 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.
NOTE
Perform bleeding operation starting with rear
brake caliper farthest from master cylinder
and then at front caliper of the same brake
line. Do the same on the other brake line.

1) Fill master cylinder rese rvoir with brake fluid and
keep at least one-half full of fluid during bleeding
operation.
Brake fluid
: Refer to reservoir cap (1) 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 cy linder 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 referring to “Front Disc
Brake Components in Section 4B” and “Rear Disc
Brake Components in Section 4C”.
1. Right front brake caliper 3. Right rear brake caliper
2. Left front brake caliper 4. Left rear brake caliper
I6RS0C410007-01
1
I6RS0C410009-01
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Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-11
Brake Hose and Pipe InspectionS7RS0B4106009
Hose
The brake hose assembly should be checked for road
hazard damage, for cracks and chafing of outer cover,
for leaks and blisters. A light and mirror may be needed
for an adequate inspection. If any 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.
Master Cylinder ComponentsS7RS0B4106010
I4RS0B410009-01
10
11
1
2 3
4
5 7
13
12
9
FLD
8FLD
6FLD
(b)
(a)
(c)FLD
I7RS0B410004-01
1. Reservoir cap 7. Master cylinder piston set13. Circlip
2. Filter 8. Primary piston assembly
: Apply brake fluid. :2.5 N
⋅m (0.25 kgf-m, 2.0 lb-ft)
3. Reservoir 9. Secondary piston assembly
: Apply brake fluid. : 15 N
⋅m (1.5 kgf-m, 11.0 lb-ft)
4. Grommet : Apply brake fluid. 10. Cup
: 16 N.m (1.6 kgf-m, 12.0 lb-ft) (flare nut for
M10)
19 N.m (1.9 kgf-m, 14.0 lb-ft) (flare nut for
M12)
5. Secondary piston stopper pin : Apply brake fluid. 11. Piston guide
: Do not reuse.
6. Master cylinder body : Apply brake fluid to inside of cylinder. 12. O-ring

Downloaded from www.Manualslib.com manuals search engine 4A-14 Brake Control System and Diagnosis:
6) Fill reservoir with specified fluid.
7) After completing the work, bleed air from brake and clutch system referring to “Air Bleeding of Brake
System” and “Air Bleeding of Clutch System in
Section 5C” (M/T model).
8) Install cowl top panel referring to “Cowl Top Components in Section 9K”.
9) Install windshield wiper referring to “Windshield
Wiper Removal and Insta llation in Section 9D”.
10) Perform brake test and check each installed part for fluid leakage.
Master Cylinder Assembly Disassembly and
Assembly
S7RS0B4106013
Disassembly
1) Push in primary piston (1) to remove secondary
piston stopper pin (2) from master cylinder as
shown.
2) Remove circlip (1).
3) Remove piston guide and primary piston. Then remove secondary piston by blowing compressed air
(2) into hole. Be cautions during removal as
secondary piston jumps out.
WARNING!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth to prevent piston from
damage. It should be taken out gradually with
moderately compressed air. Do not place
your fingers in front of piston when using
compressed air.

Assembly
CAUTION!
• Never use any mineral oil such as kerosene oil and gasoline when washing
and assembling parts.
• Check inside of cylinder wall, pistons and cup seals are free from any foreign objects
such as dust and dirt and use case not to
cause any damage with a tool during
assembly.
• Do not drop parts. Do not use any part which has been dropped.

1) Apply brake fluid to inside of cylinder and contact surface of piston assembly (new piston cups, new O-
ring and piston guide).
2) Install secondary return spring and secondary piston (1) into cylinder body (4).
NOTE
Align oblong hole in secondary piston (2)
with stopper pin hole (3) in master cylinder
body (4) when installing it.

3) Install primary piston assembly into cylinder body.
4) Install piston stopper pin (2) with pistons pushed in all the way and install it.
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I4RS0A410017-01
I2RH01410027-01
I4RS0A410018-01

Downloaded from www.Manualslib.com manuals search engine 4B-4 Front Brakes:
Installation1) Torque caliper pin bolts (a) to specification.
NOTE
• Make sure that boots are fit into groove securely.
• If brake pads are replaced, use new caliper pin bolts included in repair kit. (if included)

Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
2) Connect caliper to flexible hose.
3) Torque flexible hose jo int bolt to specification.
Tightening torque
Flexible hose joint bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
WARNING!
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.

4) Tighten bleeder plug to specified torque. Tightening torque
Bleeder plug (c): 8.0 N·m (0.8 kgf-m, 6.0 lb-ft)
5) Lower hoist and torque wheel nuts to specifications. Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) After completing installation, fill reservoir with brake
fluid and bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
7) Check each installed part for fluid leakage.
8) Perform brake test and check fluid leakage.
Front Disc Brake Caliper Disassembly and
Assembly
S7RS0B4206006
Disassembly
CAUTION!
• Clean around caliper with brake fluid before disassembly.
• Be careful not to damage inside (bore side) of cylinder.

1) Remove piston with air blown into flexible hose bolt installation hole.
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 fingers in front of piston
when using compressed air.

2) Remove cylinder boot.
3) Remove piston seal using a thin blade like a thickness gauge, etc.
4) Remove bleeder plug and cap from caliper.
(a)
I4RS0A420003-01
I6RS0C420004-01
I2RH01420011-01
I2RH01420013-01

Downloaded from www.Manualslib.com manuals search engine 4B-6 Front Brakes:
5) To confirm that boot is fitted in its groove in cylinder
properly, pull piston out of cylinder a little but do not
take it all out.
NOTE
Boot’s face (1) should be at the same level
from cylinder’s face (2) all around.

6) Insert piston into cylinder by hand.
Front Disc Brake Caliper InspectionS7RS0B4206007
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
Front Brake Disc Removal and InstallationS7RS0B4206008
CAUTION!
During removal, be care ful not to damage
brake flexible hose and not to depress brake
pedal.

Removal
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper carrier bolts (2 pcs).
NOTE
Hang removed caliper with a wire hook or the
like so as to prevent brake hose from
bending and twisting excessively or being
pulled.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
I4RS0A420004-01
I2RH01420014-01
I2RH01420015-01
I2RH01420024-01
I2RH01420025-01

Downloaded from www.Manualslib.com manuals search engine 4C-8 Rear Brakes:
Rear Disc Brake Caliper InspectionS7RS0B4306006
Pin Boot and Cylinder Boot
Check boots (1) for breakage, crack and damage.
If defective, replace.
Disc Brake Piston
Check all around piston for rust, corrosion and any other
damage.
If it is found faulty, replace.
Caliper
Push in adjusting bolt (1) by hand and move lever to
check that adjusting bolt (1) moves smoothly in the
arrow direction.
Also, check adjusting bolt (1) for any damage. If it is
found faulty, replace.
Slide Pin
Check guide pin for smooth movement.
If it is found faulty, correct or replace.
Apply rubber grease to guide pin outer surface. Rubber
grease should be the one whose viscosity is less
affected by such low temperature as –40 °C (–40 ° F).
Rear Flexible Hose Removal and InstallationS7RS0B4306007
Removal
1) Hoist vehicle and remove tire and wheel.
2) Remove caliper (4) assembly referring to “Rear Disc Brake Caliper Disassembly and Assembly”.
3) Loosen brake pipe flare nut (1) using by flare nut wrench.
4) Remove clip (2).
5) Remove brake flexible hose (3) from brake pipe.
Installation
Install reverse order of removal nothing the following.
• Tighten brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0 lb-ft)
1 1
1
I6RS0B431019-01
I6RS0B431020-01
1
I6RS0B431021-01
1
2
3
4
I6RS0C430013-01

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS7RS0B4406001
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 stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has been depressed at least 3 times with about
160 N (16.0 kg, 35.3 lbs) load.
• Parking brake lever (1) has been pulled up a few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N ⋅m (50 kg, 110 lbs)
force.

1) Release parking brake lever (1).
2) Loosen parking brake lever adjust nut (2) fully.
3) Make sure that lever (3) contacts pin (4).
4) Pull up parking brake lever 1 notch.
5) Rotate rear wheel by hand and fasten parking lever adjust nut until dragging rear wheel lightly.
I4RS0B440002-01
1. Parking brake cable 2. Brake caliper
I4RS0A440003-01
I6RS0C440001-01
I6RS0C440002-01