SAFARI

18 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