SAFARI

BRAKES

INSPECTION

Fig. 12

Clean all parts thoroughly with fresh brake fluid.Never

use mineral oil like kerosene, petrol, diesel etc. After

thoroughly cleaning, examine all parts for damages

and corrosion.

PISTON

Outer surface should be free from nicks, score or rust

and should be smooth to touch. Caliper housing bore

should be free from score, pitting, corrosion and should

be smooth to touch.The seal groove in the bore should

be thoroughly cleaned and no nicks should be there

at the edges. If the above conditions are quite

satisfactory then replacement with appropriate kit will

give satisfactory performance. If not the caliper

assembly should be replaced. Do not use emery paper

on piston surface.

SLIDING PINS

Should be free from rust and bends and guide pin

dust covers should be soft and free from cracks or

puncture. If in doubt, replace them.

PISTON SEALING RING

Piston sealing ring is used to seal piston and cylinder

and it is used to adjust the clearance between pad

and disc. Replace the piston sealing ring with a new

one at every overhaul. Fit piston sealing ring into

groove in the cylinder taking care that it should not be

twisted.

CALIPER ASSEMBLY

Smear fresh brake fluid on to the sealing ring and fit it

on to the groove in the cylinder bore. Smear fresh

brake fluid to the bore and on piston surface. Assemble

dust cover on to the piston by reversing the dust cover.

Now push the piston gradually into the bore until it

reaches the bottom. Fit the other end of the dust cover

on to the caliper body. Smear sliding pins with special

red rubber grease. Insert the loose guide pin into the

top hole of the bracket and fit the dust cover on to the

carrier. Now fit the caliper assembly to the carrier in

the reverse order of removal.

DISC INSPECTION

Before assembling the caliper back to the carrier, the

disc should be inspected.

The disc should be free from score marks. If scores

are found, this should be ground and refitted. But at

no time more than 0.25 mm (0.010") material should

be ground per side. If the total thickness of the disc

after grinding is found to be less than 19.00 mm, the

disc should be changed. After fitment, the face run

out of the disc should be less than 0.10 mm otherwise

pedal pulsation will be felt during brake applicable.

The disc thickness variation to be checked by

measuring the thickness of disc at 4 or more points

around the circumference of disc. All measurements

must be made at the same distance from edge of the

rotor. During the measurement confirm that the dial

gauge probe to be approx. 10 mm from the outer edge

of the brake rotor, perpendicular to the disc and under

slight pre load. Check front wheel bearing for looseness

before face run out measurement. The control of the

braking surface finish is necessary to avoid pulls and

erratic performance. It will also help in extending pad

life.

Fig. 12