Diagnostic Information And Procedures; Brake Symptom Diagnosis; Repair Instructions; Brake Pedal Height Inspection And Adjustment - Suzuki RMX450Z Service Manual

Brake Symptom Diagnosis

Condition
Insufficient brake power
Brake squeaking
Excessive brake lever
stroke
Leakage of brake fluid
Brake drags

Brake Pedal Height Inspection and Adjustment

Refer to "Brake System Inspection" in Section 0B
(Page 0B-22).

Brake Fluid Level Check

Refer to "Brake System Inspection" in Section 0B
(Page 0B-22).

Brake Hose Inspection

Refer to "Brake System Inspection" in Section 0B
(Page 0B-22).

Air Bleeding from Brake Fluid Circuit

Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full
braking performance of the brake caliper. The presence
of air is indicated by "sponginess" of the brake lever and
also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider, it
is essential that after remounting the brake and restoring
the brake system to the normal condition, the brake fluid
circuit be purged of air in the following manner:

Diagnostic Information and Procedures

Possible cause
Leakage of brake fluid from hydraulic
system.
Worn pads and disc.
Oil adhesion on friction surface of pads. Clean disc and pads.
Air in hydraulic system.
Not enough brake fluid in the reservoir. Replenish.
Carbon adhesion on pad surface.
Tilted pad.
Damaged wheel bearing.
Loose front wheel axle or rear wheel
axle.
Worn pads and disc.
Foreign material in brake fluid.
Clogged return port of master cylinder.
Air in hydraulic system.
Insufficient brake fluid.
Improper quality of brake fluid.
Insufficient tightening of connection
joints.
Cracked hose.
Worn piston and/or cup.
Worn piston seal and dust seal.
Rusty part.
Insufficient brake lever or brake pedal
pivot lubrication.

Repair Instructions

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BA02J24106002
BA02J24106003
BA02J24106004
Brake Control System and Diagnosis:
Correction / Reference Item
Repair or replace.
Replace.
Bleed air.
Repair surface with sandpaper.
Correct pad fitting or replace.
Replace.
Tighten to specified torque.
Replace.
Replace brake fluid.
Disassemble and clean master cylinder.
Bleed air.
Replenish fluid to specified level; bleed air.
Replace with correct fluid.
Tighten to specified torque.
Replace.
Replace piston and/or cup.
Replace piston seal and dust seal.
Clean and lubricate.
Lubricate.
CAUTION
!
Handle brake fluid with care: the fluid reacts
chemically with paint, plastic, rubber
materials, etc.
Front Brake
1) Remove the reservoir cap (1) and diaphragm.
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1
IA02J1410002-01
4A-3