Maintenance Of Front/Rear Brake - ZONGSHEN ZS250GY-3 Service Manual

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:
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.
4 The cause,trouble description and repair method of front/rear brake
Table 3-11
Component
Description
Brake pads
Brake cam
44
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

Maintenance of Front/Rear Brake

Cause
Friction plates are worn.
The end of brake pad is
worn to a slot.
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.
The elasticity of brake
s h o e s p r i n g i s n o t
enough or broken.
Moving parts are rusty or
have foreign things.
T h e c i r c l e s u r f a c e o f
brake cam is worn.
Trouble description Trouble description of mot
of component
Brake is out of control or
brake pads cannot return.
Rear brake makes abnormal
sound or is out of control.
Brake is out of control .
Brake pads cannot return. R e p l a c e r e t u r n
The rotation of brake Brake is out of control or
cam is not flexible. cannot return.
Brake is out of control .
C o o p e r p a c k i n g
connecting bolt,
required torque:
30N.m±2N.m
Repair method
orcycle
R e p l a c e b r a k e
pads as a set.
Repair or replace
friction plates of
brake pads
spring.
Clean and lubricate
brake cam.
R e p l a c e b r a k e
cam.