BRAKES 32 F. BRAKE LIGHT SWITCH ADJUSTMENT 1. Place the brake pedal in release position. 2. Hold the pedal in release condition by one hand & insert the switch in to the adjuster by other hand. 3. Insert the switch till the plunger is completely depressed & body of switch is touch to pedal. 4. Turn the switch at that moment to clockwise. This movement create the gap of 1 mm between switch & pedal. 5. Ensure the pedal is free & not pressed due to switch. G. CALIPER GREASING Loosen and remove the sliding pin and grease them with the special grease which is provided for brakes. NOTE Check the sliding pin boot for any cut or damages. If any defect is found replace the boot. H. DISC RUN-OUT MEASUREMENT PROCEDURE 1. With the gear in neutral position, hoist the vehicle on two post lift and remove the front wheel. Tighten the wheel nuts on Brake disc only. 2. Mount the magnetic dial stand at an appropriate position such that the needle can be placed perpendicular to the disc face. 3. Ensure that brake disc surface is clean and dial indicator tip touching the brake disc on circle at a distance of ≈ 114 mm from wheel center. 4. Rotate the brake disc while watching the dial indicator needle movement; record the maximum value shown on the dial indicator. The maximum value is the brake disc run out. 5. The brake disc runout should not be more than 0.060 mm (60 Microns). NOTE For further inspection and repairs refer the BRAKE DISC REMOVAL in the next section. DISC INSPECTION: The disc should be free from score marks. If scored, it should be replaced. The disc thickness variation is to be checked by measuring the thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made at the same distance from the edge of the rotor. After fitment, the face runout of the disc should be less than 0.06 mm. During measurement, confirm the dial gauge probe should perpendicular to the disc and under slight preload. Check front wheel bearing for looseness before face runout measurement. The control of the braking surface finish is necessary to avoid pulls and erratic performance. It will also help in extending pad life.
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