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Maintenance of Front/Rear Brake
Table 3-11
4 The cause,trouble description and repair method of front/rear brake
Component
Description
Cause
Trouble description
of component
Trouble description of mot
orcycle
Repair method
Brake pads
Friction plates are worn.
Brake is out of control or
brake pads cannot return.
R e p l a c e b r a k e
pads as a set.
The end of brake pad is
worn to a slot.
Rear brake makes abnormal
sound or is out of control.
The area of brake shoe
t o u c h i n g w i t h b r a k e
drum is too small.
Brake is out of control .
Repair or replace
friction plates of
brake pads
The elasticity of brake
s h o e s p r i n g i s n o t
enough or broken.
Brake pads cannot return. R e p l a c e r e t u r n
spring.
Brake cam
Moving parts are rusty or
have foreign things.
The rotation of brake
cam is not flexible.
Brake is out of control or
cannot return.
Clean and lubricate
brake cam.
The circle sur face of
brake cam is worn.
Brake is out of control .
R e p l a c e b r a k e
cam.
Trouble 3: after several attempts to apply the brake, it feels like braking is soft or gone.
Cause study: 1. Poor sealing of brake fluid which leads to leakage of brake fluid; 2. Brake system vacuum
filling fails. It fails to fill brake fluid with the 2nd circuit of ABS control module; 3. Brake caliper falls off.
Methodology: 1. Check the brake lines for leakage of brake fluid and fasten the leaking points and bleed air
again.2. After bleeding, attempts are made to drive. Ensure bleeds occur again when ABS is operating until
it feels comfortable with braking (mainly for the purpose of filling the 2nd circuit of ABS control module
with brake fluid); 3. Fasten the brake caliper again.
Trouble 4: as brake is applied, the wheel is locked and can not released. There is no reacting force from
ABS.
Cause study: misled connection of brake line
Methodology: reconnect the brake line in a correct sequence which is shown in the figure below:
Interface definition
FM front wheel master cylinder
FM front wheel wheel cylinder
RM rear wheel master cylinder
RM rear wheel wheel cylinder
M u s h r o o m h e a d
c o n n e c t i n g b o l t,
required torque: 20N.
m
±
2N.m
Cooper packing
connecting bolt,
required torque:
30N.m
±
2N.m
2. The torque required for the connecting bolt for the braking system:
3. The requirements on brake fluid: DOT 4 or higher can be used only.
Summary of Contents for ZS250GY-3
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