Brake Pedal Free Height Check; Brake Light Switch Adjustment; Excessive Pedal Travel Check - Suzuki SQ416 Service Manual

1. Carpet

BRAKE PEDAL FREE HEIGHT CHECK

Check brake pedal free height.
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
(b): 7.5 N
1. Stop light switch

EXCESSIVE PEDAL TRAVEL CHECK

1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to carpet clearance "c".
CAUTION:
Make sure that carpet is attached to vehicle body tightly
when taking measurement.
Clearance "c": over 100 mm (3.94 in.)
4) If clearance "c" is less than 100 mm (3.94 in.), 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 100 mm (3.94 in.) 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 for the ve-
hicle with brake booster.
.
m (0.75 kg-m, 5.5 lb-ft)
BRAKES 5-9