Changing the world one Vehicle at a Time
NOTE: This section also applies to the FRONT brake system for the ETR100 model.
The disc brake system includes brake fluid/oil and is engaged by squeezing the left brake handle, where
the brake fluid/oil reservoir is also located. It can be inspected and maintained as follows:
1. Check the brake fluid/oil level in the reservoir. If the level falls below the bottom score line, add
ONLY either DOT3 or DOT4 brake fluid/oil until it reaches the upper score line.
NOTE: A drop in the brake fluid/oil level indicates potential plate friction, brake disc wear or
brake fluid leakage, and further inspection into these potential issues is needed.
2. If the brake fluid/oil changes color, replace it with new braking fluid/oil.
3. Check the friction plate and brake disc wear condition. When any of the friction plates is worn
down to the marking line of 3mm or
3.5mm, it must be replaced in pairs. The disc brake thickness and wear limits may differ slightly from
Pushpak model to model.
4. If the left brake handle is spongy or has little resistance or effectiveness when squeezed, exhaust
the left brake system as follows:
i. Remove the main cylinder cover and add brake fluid/oil until the fluid level reaches the upper
score line. Close the cover to prevent debris from entering.
ii. Use a hose with one end connected to the caliper oil drain screw and the other end to an
appropriate container.
iii. Quickly squeeze and release the left hand brake a few times, and then hold the hand brake in
place on the last squeeze.
iv. While the hand brake is being held in place, loosen the air release screw by turning it
counterclockwise one quarter inch. This will allow any foamed brake fluid/oil to be released
through the hose and into the container.
v. Tighten the air release screw.
vi. Repeat steps 3 through 5 until all of the foaming brake fluid/oil is emptied and the brake handle is
no longer spongy and has proper resistance and effectiveness.
vii. Tighten the drain screw and disconnect the drainpipe.
viii. Add brake fluid/oil to the main cylinder until it reaches the upper score line.
ix. Close the cover.
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