Brake Pedal Free Height Check; Brake Light Switch Adjustment; Excessive Pedal Travel Check - Suzuki sq-416-420-625 Service Manual

BRAKE PEDAL FREE HEIGHT CHECK

Remove foot rest and displace carpet and dash silencer(s) so as to
measure brake pedal free height between pedal face and asphalt
sheet installed on dash panel.
Brake pedal free height "a" from asphalt sheet:
208 – 218 mm (8.19 – 8.58 in.)
If the measurement is not within the specification, check the posi-
tion of booster push rod clevis and/or stop light switch according
to the instruction shown in this section.
The free height varies depending on installation position of booster
push rod clevis and stop light switch.

BRAKE LIGHT SWITCH ADJUSTMENT

Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust switch
position so that clearance between end of thread and brake pedal
return cushion (shown as "b" in figure).
Then tighten lock nut to specified torque.
Clearance "b": 1.5 – 2.0 mm (0.06 – 0.08 in.)
Tightening Torque
1. Stop light switch
(b): 7.5 N

EXCESSIVE PEDAL TRAVEL CHECK

1) Remove foot rest and displace carpet and dash silencer(s).
2) Start engine.
3) Depress brake pedal a few times.
4) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to asphalt sheet clearance "c".
Clearance "c": over 115 mm (4.53 in.)
5) If clearance "c" 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 "c" remain less than specification even after
replacement of brake shoes and bleeding of system, other pos-
sible but infrequent cause is malfunction of rear brake shoe ad-
justers or booster push rod length out of adjustment.
.
m (0.75 kg-m, 5.5 lb-ft)
BRAKES 5-9