SAFARI BSVI - SERVICE MANUAL

BRAKES (Non EPB) 28 6. Keep the wooden piece in between the piston and the caliper housing and blow dry compressed air into the caliper gradually through the inlet port (Where banjo bolt is connected). Now you will observe the piston coming out of the caliper gradually. 7. Remove the piston from the caliper housing. 8. Remove the piston boot from the caliper housing. 9. Remove the sealing ring from the groove in the caliper housing. 10. Remove the bleed screw from the caliper housing. INSPECTION Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. After thoroughly cleaning, examine all parts for damages and corrosion. Check the various parts for the following: 1. PISTON Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface. 2. CALIPER HOUSING Bores should be free from score, pitting and corrosion. The seal grooves in the bore should be thoroughly cleaned and no nicks should be there at the edges. If the above conditions are satisfactory then replacement with appropriate kit will give satisfactory performance. If not the caliper assembly should be replaced. 3. CARRIER Remove the grease from sliding pin bores and clean the bores thoroughly. The carrier-machined surface should be free from any damages; hit marks etc. and the sliding pin bores should be free from ovality and damages. Check for the carrier mounting bolts. 4. SLIDING PINS Should be free from rust, bends and step formation due to wear. If necessary, replace the sliding pin with new one. ASSEMBLY NOTE Discard all the rubber parts and the pad sliders and use new one at the time of assembly. 1. Dip the sealing rings in fresh brake fluid and fit it on to the groove in the caliper pot and work around with fingers until properly seated. 2. Smear fresh brake fluid to the pistons surface, assemble piston boot on to the piston by reversing the dust cover. 3. Smear brake fluid liberally into the bores. Now locate the piston squarely and push gradually into the bore until it reaches the bottom. NOTE If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing