Mechanical Brake Fitting & Maintenance

Mechanical Brake Fitting & Maintenance

 

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

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

 

Go to mechanical brake parts.

 

 

Introduction -  mechanical-brake.gif

This cable operated gokart brake unit is designed to give both reliable & consistant performance. This information sheet is to ensure that it is maintained at its most efficient & safe operation for its competitive life.

 

Fitting Instructions -

The 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.

brake-profile.gifThe 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 the 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.)brake-alignment-diagram.gif

Check the disc alignment, centre if required & tighten the disc carrier pinch screw. Thread the inner 'Bowden' cable through on operating arm (it is often found advantageous to fit a compression spring over the inner cable between the two operating arms) then through the other operating arm. Ensure that the inner cable is clean & feed it into the outer 'Bowden' cable. Route the assembled inner & outer cables to the brake operating perdal, making sure there are no sharp bends or kinks. Fit outer to the chassis & inner to the pedal by the means provided on your gokart chassis. Test the brake pedal movement. Any slack should be eliminated by means of the outer cable adjuster NOT THE LEVER ARM ADJUSTER, on the caliper. The lever arm adjusters are set at the factory to come out of the casting at approximately 15 degrees increasing their leverage as they come to the upright position of the max mechanical advantage. Any maladjustment or pad wear that allows the arm beyond the upright position will descrease the mechanical advantage & therefore your braking efficiency.

 

Finally, when you are sure the gokart brake is operating & returning freely, secure the outer cable with cable ties to the top of the gokart frame tubes to keep the cable route in the free running position & out of the driver's way.

 

Service & Maintenance -Pad wear is compensated for by slackening off the M10 nylock nuts & adjusting the aluminium adjuster pillars & re-locking the M10 nylock nuts. As this will mean bringing the caliper halves closer together, the outer cable adjuster on the go-kart chassis will have to be used to remove the slack between the inner & outer cables. After prolonged use the pad return movement may become sluggish, it will then be necessary to remove the pad, clean the backing plate and the area behind, remove the pistons from their bores, clean both & re-lubricate with HMP graphited grease. Re-Assemble & adjust as above. When fitting replacement pads, DO NOT USE HARD PADS, standard pads are fitted originally but a soft pad is also available. When ordering replacement pads , specify they are for a mechanical gokart brake unit. Replace inner cable if it becomes frayed, ensure it is kept clean & lubricate it with a light oil if a PTFE lined outer cable is not used.

 

 

Maintenance & preparation are of the paramount importance as off road equipment is subject to the maximum of stress. Any suspicion of malfunction should be treated as serious especially as this is the only brake you have on the go-kart.

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For spare parts for your mechnical gokart brake caliper please visit our spares dept