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Manual Bleeding the Brakes

  1. Remove the booster reserve by applying the brakes several times with the engine OFF until all the reserve is depleted.
    Fig 1: Removing Booster Reserve By Applying Brakes
    G04103244Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: If the master cylinder is known or suspected to have air in the bore, then it must be bled before any wheel cylinder or caliper is bled.
  2. Fill the master cylinder reservoir with brake fluid. Keep the master cylinder at least one-half full of fluid during the bleeding operation.
    Fig 2: Filling Master Cylinder Reservoir With Brake Fluid
    G04103245Courtesy of SUZUKI OF AMERICA CORP.
  3. Disconnect the front brake line(s) at the master cylinder.
  4. Allow the brake fluid to fill the master cylinder until it begins to flow from the front pipe connector port.
  5. Connect the front brake line(s) to the master cylinder.

    Tighten 

    Tighten the brake lines to 16 N.m (12 lb-ft).

    Fig 3: Connecting Front Brake Lines To Master Cylinder
    G04103246Courtesy of SUZUKI OF AMERICA CORP.
  6. Slowly push and hold the brake pedal one time.
    Fig 4: Pushing And Holding Brake Pedal
    G04103247Courtesy of SUZUKI OF AMERICA CORP.
  7. Loosen the front brake line at the master cylinder to purge air from the cylinder.
  8. Tighten the brake line (as in step  5), and then release the brake pedal slowly. Wait 15 seconds before proceeding to the next step.
  9. Repeat the sequence, including the 15-second wait, until all the air is removed from the master cylinder bore.
    Fig 5: Loosening Front Brake Line At Master Cylinder
    G04103248Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Care must be taken to prevent brake fluid from contacting any painted surface to prevent damage to the paint finish.
  10. After all the air has been removed at the forward connection(s), bleed the master cylinder at the rear (cowl) connection(s) in the same manner as with the front connections.
    Fig 6: Tightening Brake Lines
    G04103249Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: For vehicles equipped with a non-antilock braking system, the bleeding sequence is as follows: right rear, left rear, left front and right front. For ABS vehicles, refer to "BLEEDING SYSTEM :" for the correct sequence and bleeding procedure.
  11. Attach a transparent tube over the valve. Allow the tube to hang submerged in brake fluid in a transparent container.
    Fig 7: Attaching Transparent Tube Over Valve
    G04103250Courtesy of SUZUKI OF AMERICA CORP.
  12. Slowly push and hold the brake pedal one time.
  13. Remove the bleeder valve dust cover and loosen the bleeder screw to purge the air from the cylinder.
  14. Tighten the bleeder screw.

    Tighten 

    Tighten the bleeder screw to 8 N.m (71 lb-in).

  15. Slowly release the brake pedal. Wait 15 seconds before proceeding with the next step.
    CAUTION: Rapid pumping of the brake pedal pushes the master cylinder secondary piston down the bore in a manner that makes it difficult to bleed the system.
  16. Repeat the sequence, including the 15-second wait, until all the air is removed. It may be necessary to repeat the sequence 10 or more times to remove all the air.
  17. Locate the front bleeder caps.
    Fig 8: Loosening Bleeder Screw
    G04103251Courtesy of SUZUKI OF AMERICA CORP.
  18. Proceed to bleed the front brakes following the appropriate sequence, beginning with step  12.
  19. Check the brake pedal for spongeness. Repeat the entire bleeding procedure to correct this condition.
  20. Replace the bleeder valve dust cover.
    Fig 9: Tightening Bleeder Screw
    G04103252Courtesy of SUZUKI OF AMERICA CORP.
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