Suzuki AN400 - Diagnostic Information and Procedures; Brake Symptom Diagnosis; Repair Instructions; Brake Light Switch Inspection

4A-3 Brake Control System and Diagnosis:
Diagnostic Information and Procedures
Brake Symptom Diagnosis
B705H14104001
Repair Instructions
Brake Light Switch Inspection
B705H14106008
Front Brake Light Switch
Inspect the front brake light switch in the following
procedures:
1) Remove the handlebar cover. Refer to “Handlebar
Cover Removal and Installation in Section 9D
(Page9D-13)”.
2) Disconnect the front brake light switch lead wire
couplers (1).
3) Inspect the switch for continuity with a tester.
If any defects are found, replace the front brake light
switch with a new one. Refer to “Front Master
Cylinder / Brake Lever Disassembly and Assembly
(Page4A-9)”.
Special tool
: 09900–25008 (Multi-circuit tester set)
Tester knob indication
Continuity ( )
Front brake light switch
4) Connect the front brake light switch lead wire
couplers.
Condition Possible cause Correction / Reference Item
Insufficient brake power Leakage of brake fluid from hydraulic
system.
Repair or replace.
Worn pads. Replace.
Oil adhesion on friction surface of pads. Clean disc and pads.
Worn disc. Replace.
Air in hydraulic system. Bleed air.
Not enough brake fluid in the reservoir. Replenish.
Brake squeaking Carbon adhesion on pad surface. Repair surface with sandpaper.
Tilted pad. Correct pad fitting or replace.
Damaged wheel bearing. Replace.
Loose front-wheel axle or rear-wheel
axle.
Tighten to specified torque.
Worn pads or disc. Replace.
Foreign material in brake fluid. Replace brake fluid.
Clogged return port of master cylinder. Disassemble and clean master cylinder.
Excessive brake lever
stroke
Air in hydraulic system. Bleed air.
Insufficient brake fluid. Replenish fluid to specified level; bleed air.
Improper quality of brake fluid. Replace with correct fluid.
Leakage of brake fluid Insufficient tightening of connection
joints.
Tighten to specified torque.
Cracked hose. Replace.
Worn piston and/or cup. Replace piston and/or cup.
Brake drags Rusty part. Clean and lubricate.
Insufficient brake lever or brake pedal
pivot lubrication.
Lubricate.
Malfunction of brake-lock. Adjust or replace.
1
I705H1410001-01
Terminal (B/Bl) Terminal (B/R)
Color
Position
OFF
ON
I705H1410020-03