Hydraulic Brake Fitting & Maintenance

Hydraulic Brake Fitting & Maintenance

 

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The following are detailed instructions for fitting & maintaining our standard hydraulic gokart brake.


For further advice please do not hesitate to contact us directly.

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Introduction - 

The brake system supplied with your gokart is designed to give both reliable & consistent performance. Both the caliper & master cylinder pistons are fitted with twin seals which will give you the security that a single gokart brake system must provide.


Fitting instructions -

brake-profile.gifThe disc must be fitted to the axle & the disc carrier pinch screw not tightened so that the disc assembly can be slid to its approximate position.

The caliper assembly is slid over the disc & positioned so the 8mm fixing holes in the caliper align with the gokart fixing holes on the brake mounting bracket, ensuring sufficient spacers are fitted between the caliper casting & the kart bracket to ensure free movement of the brake operating arm on that side & that the M6 screw & locknut do not foul the gokart bracket.

 

Fit the 8mm fixing screws & lightly tighten ensuring the disc is roughly centred between the pads. At this stage determine if the pads are parallel & square to brake-alignment-diagram.gifthe disc. A small degree of non-alignment is permissable (approx. 1mm over the pad length) - any further out of parallel must be corrected by the use of shims under the caliper mounting face. The gap between the pad faces & disc is, to a degree, a matter of personal preference but must not exceed 2mm. Adjustment of this gap is achieved by loosening the two M10 nylock nuts 7 screwing the aluminium adjuster pillars in or out to achieve the desired gap. Then retighten the M10 nuts & finally tighten the caliper to the gokart bracket. (Loctite on the bracket to the caliper fixing screws is recommended.)

Check the disc alignment, centre if required & tighten the disc carrier pinch screw. Fix the master cylinder to the gokart mounting bracket, again using Loctite for security. Ensure the hydraulic pipe is run on the top of the frame tubes & secured using cable ties.

 

Use & adjustment -

The pad return springs genrate a powerful force to clear the pad from the disc. If the pad becomes sluggish remove the pads & clean the area behind with a dry cloth or brush. Operate master cylinder carefully to expose the caliper pistons as far as the 'O' ring groove only, clean & lubricate with Girling or Pearl Products rubber grease, then allow the piston to retract into the caliper. This should only be necessary after a long period of non-use. The unit comes supplied, primed & bled with Dot 4 'universal' brake fluid. It is afdvisable after a year orbefore a new season of off-roading to drain & replace the brake fluid. Examination of caliper lip seals and 'O' rings for wear, can be done at this point - replace if necessary, generously lubricating each with rubber grease before re-assembling. The following procedure should be followed to prime & bleed the system -

  1. Remove the master cylinder filler plug & caliper bleed screws. Ensure system is empty of all old fluid.
  2. Fit new fibre washers to bleed screws, position master cylinder higher than the caliper. Fill master cylinder with new fluid keeping a steady constant flow until a bubble-free flow of clean fluid comes from the bleed hole, then fit bleed screws & tighten firmly. Top up master cylinder to the operating lever lightly to ensure the pistons contact the back of the pads. Release thumb, then lever.
  3. Top up master cylinder, fit & tighten filler plug. Apply full pressure to the master cylinder level & check for leaks, sponginess (air in the system) & prompt return of the pads. Re-tighten any fitting that leaks. if pad return is not prompt, caliper pistons need cleaning & lubricating or in rare cases, the master cylinder piston will need cleaning & lubricating. If sponginess of lever is felt proceed to step 4.
  4. Crack open (2 turns) the bleed screws, operate master cylinder lever slowly until air bubbles cease to bubble out of the side of the bleed screws, tighten bleed screws. Crack open filler plug, before releasing operating lever. Then repeat step 3.

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Maintenance & preparation are of paramount importance as off road equipment is subject to the max of stress. Any suspicion of leaking or malfunction should be treated as serious, especially as this is the only brake you have on your gokart. Replacement seal kits & spare parts are available for your hydraulic brake.

Please visit our spares page.