ZEST BOLT Service Manual

BRAKES 2 7.2 TECHNICAL SPECIFICATIONS Applicable to all models (1.3 QUADRAJET and 1.2 REVOTRON) BOLT and ZEST. SPECIFICATIONS FRONT REAR Brake Type Disc Brakes with single pot floating type caliper Leading and Trailing Drum Brakes with auto adjuster Brake Details Caliper piston dia. = 54mm Drum Size = 200 X 30 mm(BOLT / ZEST) Disc diameter = 254 mm Drum inside dia. = 200 mm Disc thickness = 22 mm Max. rebore dia. = 202 mm Discard thickness = 20 mm Out of round = 0.04 mm Wheel Cylinder dia. =19.05 mm Lateral run - out = 0.03 mm Disc Thickness variation (max) Radial = 0.03 mm Circumferential = 0.01 mm Brake lining area 94 cm² per brake (BOLT / ZEST) 115.2 cm² per brake(BOLT /ZEST) 192x30x4.5 (BOLT / ZEST) Type of lining Moulded - Asbestos Free Moulded - Asbestos Free (Bonded Lining Replacement service limits for pad/lining Brake pads should be replaced when it’s thickness reaches below 6 mm Up to 1mm of liner thickness from shoe- rim surface is permissible Parking Brakes Not Applicable Lever type, cable operated mechanical linkages acting on rear wheels Tandem Master Type = Fixed Seal Cylinder (TMC) details Size = 19.05 mm dia Material = Aluminum Finish = Anodized Stroke = 38 mm (Primary : 19mm and Secondary : 19mm) Circuit = Diagonal split (Primary to FL & RR) (Secondary to FR & RL) Vacuum Servo details Type = Light shell compact Size = 10 inch Boost Ratio = 7 : 1 Brake Pedal Details Free Play = 8 mm Height = 200 mm Stroke = 120 mm Brake Fluid Details Type: DOT4 confirming to SAE J1704