Liangzi Power UTV1000-3, Maintenance Manual

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9. BRAKES SYSTEM
9- 4
BRAKE CALIPER
Removal
Loosen wheel nuts.
Raise vehicle and support it securely.
Remove appropriate wheel.
Remove the caliper bolts then the caliper. If the caliper is not being remove from the vehicle as
during brake pad replacement,simply hang the caliper with a piece of wire to take the weight off
the brake hose.
If the caliper is being removed for replacement, drain brake system before removing the banjo
fitting and its sealing ring. Remove the caliper from the vehicle.
Catch spilled fluid with a rag. Attach the brake hose in a position to prevent the fluid from flowing
out.
Disassembly
Remove brake pads.
Remove slide caliper support and pad spring.
Place rag over piston.
Place caliper body with piston down and apply small squirts of air pressure to the fluid inlet to
remove piston.
Remove piston seal.
Clean piston grooves, caliper cylinder and piston with clean brake fluid.
Clean slide pins with brake cleaner and a rag.
Inspection
If boots are deteriorated or hard, replace with new ones.
Check caliper cylinder for scratches, rust or other damages. If so, replace caliper.
Check piston for scratches, rust or other damages. If so, replace caliper.
Assembly
Coat piston seal with clean brake fluid and install it into piston grooves in caliper.
Coat piston with clean brake fluid and install into cylinder with the closing toward caliper body.
Apply dielectric grease into sliding bores and install slide pins.
Install pad spring, caliper bracket and pads.
Installation
For installation,reverse the removal procedure, pay attention to the following details:
Use new sealing washers when installing banjo fitting retaining brake hose to caliper.
Install caliper in its original position.
Bleed the brake system
Check for leaks and make sure the brakes operate normally before driving.
BRAKE LIGHT SWITCH
The brake light switch is located on the brake
master cylinder. It can not be adjusted.
Brake light
switch