Operator`s manual

43
SECTION 7
MAINTENANCE INFORMATION
15. The emergency/parking brake should be checked for
proper adjustment every 25 hours. Note: Oil on the brake
disc caused by improper chain oiling can permanently
reduce the effectiveness of all brake systems.
850-98 Emergency/Parking Brake Kit is available for
servicing of the emergency/parking brake pads on Avengers
and Frontiers. The kit includes all necessary components and
detailed servicing instructions.
Both left and righthand side emergency/parking brake
caliper pads should be changed in pairs. Do not attempt
to just replace one side.
7.3.7 BRAKE PLUNGER ADJUSTMENT
IMPORTANT
It is critical that the master cylinder pistons are adjusted
properly when the steering handlebars are in the centred
position. Overheating of the brake system could occur
due to the piston being adjusted too far in. This could
cause a drag on the system and a possible brake lockup
or brake fade. On the other hand, the piston being
adjusted too far out increases the distance the piston is
required to travel to provide brake pressure. This can
result in the steering arm contacting and/or bending the
plunger pin guide tab resulting in compromised system
operation.
1. Remove the rewall.
2. Pull back the rubber boot at both master cylinder plunger
pins and check each piston location relative to the face of
the master cylinder casting as illustrated in Figure 7-24.
Use a straight edge against the face of the casting to ensure
the piston is between zero and 0.5 mm depth in the master
cylinder.
3. If adjustment is needed, loosen the jam nut and thread the
adjustable plunger pin either in or out as necessary.
4. Loosen the set screw on each of the plunger pin collars and
push them up against the plunger pin guide tabs. Apply
Loctite # 242 to the set screw threads and re-secure the
set screws.
Figure 7-24. Location of piston.
7.3.8 BRAKE COOLING SYSTEM
Some vehicles with hydraulic brakes have a 12 volt fan forc-
ing cool air from outside the engine compartment onto the
brake components to protect the system from overheating.
Overheating can damage the hydraulic brake components.
Make sure the brake cooling fan is operating when the vehicle
is being driven. The fan operates when the ignition switch is
in the “run” position. Keep the brake cooling system in good
working order by:
• cleaning debris from the air intake screen and ducts.
• keeping electrical connections tight and components se-
curely mounted.
Note: HDi and HD models - no cooling fan is required.
7.3.9 ENGINE COOLING & EXHAUST SYSTEM
Engine cooling air is drawn in on the right side of the engine
compartment and expelled with the exhaust on the left side.
Keep all ducting and screening in place.
Coolant Recommendations - Kohler Aegis
Use equal parts of ethylene glycol (anti-freeze) and water only.
Distilled or deionized water is recommended, especially in ar-
eas where the water contains a high mineral content. Propylene
glycol based anti-freeze is not recommended.
This mixture will provide protection from -37º C (-34º F) to
108º C (226º F). For protection and use outside the indicated
temperature limits, follow the anti-freeze manufacturers
instructions on the container, but do not exceed 70% anti-
freeze.
DO NOT use anti-freeze with stop-leak additive(s), or put any
other additives in the cooling system.