SAFARI

45 BRAKES SERVICE CHECK A. INSPECTION (As per recommended service schedule) Check the tightness of the mounting nuts (torque 20 Nm) B. OPERATING TESTS l Check for free movement of the push rod without binding whi le applying/releasing brakes. l Check for vacuum leak in brakes applied / released position by observing the vacuum gauge and ensure that the pipe lines and the joints are free from leakage. REMOVAL 1. Place wheel chokes in front and behind the wheels to prevent movement of the vehicle. 2. Remove the brake pedal return spring 3. Remove the fork pin of vacuum brake valve 4. Disconnect the hydraulic lines 5. Remove the master cylinder 6. Disconnect vacuum line connected to Non Return Valve. 7. Loosen the mounting buts of vacuum brake valve and remove the unit DISASSEMBLY 1. Clean the exterior of the unit. 2. Loosen Nut (A/F 17) on Fork and remove Fork, Gaiter, Retainer and Filters. 3. Loosen Nuts (A/F 13) on Spacer & Remove spacer and sealing ring. 4. Remove the Non return valve and Grommet. 5. Mark the position of the front & rear housing to ensure proper orientation of master cylinder mounting bolts in front housing with respect to the rear housing-mounting bolts. 6. Place and position the unit in the dismantling / assembly fixture while fixture is clamped on a bench vice. 7. Place and position the swivel block on the front housing. 8. Tighten the fixture handle to rest on the swivel block. Avoid over tightening. 9. Rotate the rods and match the notches & dimples in line. Do not over rotate otherwise the assembly will get locked again. If loosening is difficult, loosen the handle slightly and then rotate the rods. 10. After the front housing gets unlocked loosen the fixture handle slowly until the front housing gets separated fully. 11. Remove the Spring, Push rod, Spring seat and Rubber reaction disc. 12. Remove the Key retainer. 13. Press the Operating rod and remove Key. 14. Remove the operating rod assembly from the valve body by pulling it out at the fork end. 15. Separate cover and rear housing assembly. 16. Lift the Diaphragm on rear housing from the groove. 17. Remove theRetainer, Spacer and Seal fromRear housing. CLEANINGAND INSPECTION 1. Wash and clean all metal parts and blow dry with compressed air. 2. Inspect all the parts for excessive wear and deterioration. 3. Check Valve body bore and outer diameter for any score mark / crack / damage. 4. Check for any excessive wear in rubber reaction disc. 5. Check for any damage in valve rubber cup in operating rod assembly. 6. Check for any damage or holes or cut marks on Diaphragm. REASSEMBLY 1. Use recommended repair kit and diaphragm to replace old parts 2. Lubricate all moving parts (except diaphragm) with Silicone grease. This grease is supplied along with repair kit. 3. Press in the Seal, Spacer and Retainer in the rear housing using a soft mandrel and ensure that the Seal seats properly on the rear housing.