SAFARI BSVI - SERVICE MANUAL

BRAKES (Non EPB) 21 12.REGULAR MAINTENANCE A. BRAKE BLEEDING PROCEDURE CAUTION  Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water.  Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. NOTE  Always use the brake fluid recommended in the specification list.  Do not reuse the drained fluid.  Entire bleeding operation should be done with ENGINE ON (running). Always use brake fluid from the sealed bottle.  The reservoir on the master cylinder must be at the Max (upper) level mark at the start of bleeding procedure and check after bleeding each brake caliper and same have to be topped up as required. 1. Open the bonnet. 2. Open the reservoir cap and pour brake fluid till the lower edge of the filler neck. CAUTION At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. 3. Connect the bleed tube to the rear right caliper bleed screw and place the other end submerged in a transparent container containing sufficient brake fluid. 4. Depress the brake foot pedal for 2-3 times and hold it down. 5. Open the bleed screw . The fluid will flow into the transparent container. 6. Tighten the bleed screw to torque 0.9~1.3 Kgm (Rear Caliper) and 0.7~1Kgm (Front Caliper) and release the pedal. 7. After the pedal returns, allow an interval of 3 to 4 seconds before making the next stroke. Steps 4 to 6 should be repeated until there are no more air bubbles at the end of the bleed tube. 8. Now follow the same procedure at the other wheels as per the sequence given below. 9. After the bleeding sequence is completed remove the bleed tube and place the dust cap on the bleed screw. 10.Ensure that the bleed screw is tightened to the recommended torque. 11.Ensure “MAX” level after complete bleeding. 12.Clean the filter in bottle if necessary. 13.Place filter and cap to the reservoir. NOTE  If the bleeding of any caliper continues without success for a considerable time, then tighten the bleed screw after each downward stroke of the pedal, allowing the pedal to return back.  After the bleeding is done check for any leaks in the bleed screw by applying the brake pedal hard.