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SPONGY PEDAL 1.Air in the brake system.
2.Wrong size master cylinder.- .(too small).
3.Calipers not mounted square to rotor.
4.Calipers mounted equal to or higher than master cylinder.
5.Pedal ratio too great.
BRAKES DRAG 1.Rotors warped.
2.Tapered brake pads.
3.Bad master cylinder.
4.Residual pressure valve in system.
5.Calipers not square to rotor.
OSCILLATION FEED BACK 1.Excessive rotor run out.
2.Excessive front bearing clearance.
4.Rotor faces not parallel.
5.Pad material build-up on rotors.
LOSE YOUR PEDAL DURING RACE 1.Fluid boiling due to wet fluid or foot
2.Faulty master cylinder.
3.Leak in caliper or hydraulic lines.
4.Undersize brake system.
CAR WON'T STOP / HAVE TO PUSH TOO HARD ON PEDAL 1.Glazed pads or rotor.
2.Master cylinder too large.
3.Insufficient pedal ratio.
4.Wrong pad material for your application.
5.Frozen pistons in calipers.
BRAKE FLUID Due to the extreme temperatures that high
performance brake systems operate at, standard fluids are not recommended. KLRC recommends
a dot 3 or dot 4 Hi-performance fluid with the dry boiling point of 466 degrees and a wet
boiling point of 311 degrees. Dot 5 silicone fluid is not recommended because water will
collect in your system causing lower boiling points and vapor lock. Dot 5 fluid is also a
highly compressible fluid and will cause your pedal to feel spongy.
BLEEDING YOUR BRAKES When bleeding your brakes, make sure the
bleed screws are pointing up. Always start with the caliper farthest from the master
cylinder. Have one person open the bleed screw while another person slowly depresses on
the brake pedal. Close the bleed screw before brake pedal is released. Have someone keep
checking the fluid in the master cylinder. Never let the level get low. Never put fluid
drained out of the system back into the master cylinder.
If you race on a weekly basis you should
inspect your caliper seals for hardness or excessive wear at the beginning of the year and
at least once during mid season. Bad seals could cause leakage or even frozen pistons.
New brake pads require a bedding in process.
This bedding in procedure starts by pumping your brakes at a very low speed to assure
proper brake operation. then on a track make series of hard stops from moderate speed
until some brake fade is felt. Park your car and allow brakes to cool completely.
Proper breaking in of pads and rotors will result in greater
performance and longer wear.
Failure to properly bed in your pads could lead to friction material
to flake and break up resulting in fast pad wear and pad loss, or could lead to
overheating your pads and causing them to glaze over resulting in car not being able to
Brake pads should be checked regularly. If pads are wearing evenly,
the pads can be used almost down to the backing plate.
New rotors just like pads need to be bedded
in. This process is the same as the brake pads. Proper bedding will increase the rotor
life and make it more resistant to thermal cracking. Any pulsation feel will go away after
several repeated hard stops. Rotors are Blanchard ground to ensure the rotor is flat but
sometimes hubs, bearings, or hats have run-out that cause the rotor to run-out. You can
adjust the run-out by placing shims between the rotor and hub, or hat. Allowable run-out
is .005-.008. Some run-out is acceptable if you are not experiencing brake drag, pedal
pulsation or piston knock back.
Brake calipers need to be mounted square to rotor for proper
performance. After caliper is mounted onto the bracket, have someone apply the brakes
while the caliper is being observed. Only the pistons and pads should move.
The bore size of the master cylinder
influences the obtainable line pressure. Normally, when using only rear brakes a 7/8''
master cylinder is needed. If single piston front brakes are used in conjunction with rear
brakes a 1'' master cylinder will work. For using 4 piston calipers front and rear a 1
1/8'' master cylinder is recommended.
BRAKE PEDAL RATIO
Improper pedal ratio is the most common cause
of poor operation of brakes. The pedal ratio must be great enough to produce 1200 PSI
system pressure under severe braking conditions. We recommend using a pressure gauge
connected to the system to verify the maximum available pressure before running the car.
Start with a pedal ratio of 6:1 and adjust if needed.
DISC BRAKE MAINTENANCE 1.Bleed each caliper on your race car.
2.Replenish your brake system with fresh brake fluid.
3.Check for leaks around pistons and fittings of each caliper.
4.Check for leaks at any ''T'' fittings along the solid steel lines.
5.Replace any pads that are worn down.
6.Check for any burrs or dings on exposed area of piston to prevent
damaging the internal seals
during piston retraction.
7.Make sure all wheel rotate freely.
8.Check all bolts for secure tight fit.
9.Blow away brake dust with an air hose from time to time.
RESIDUAL PRESSURE VALVES Normally residual pressure valves are not
recommended. However, in some cases when the calipers are mounted at the same level or
higher than the master cylinder a 2 pound residual valve is necessary to prevent back-flow
from the caliper to the master cylinder. If a residual valve is needed it should be
plumbed just outside the master cylinder or as close as possible.
PROPORTIONING VALVES A proportioning valve restricts pressure to a
portion of the braking system, with this in mind the valve should be installed on the
brake line in which pressure needs to be reduced. A typical street vehicle normally will
use a proportioning valve in the rear line, due to most braking is done at the front
wheels. A drag racing vehicle or any vehicle using a 3.5 front wheel normally will use a
proportioning valve on the front line since most braking will be done at the rear wheels.
An adjustable valve should be used so that you can tune the brakes to your particular car.
The 31 Chapter 200 page Fuel Injection book is
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The FI book has been this price for ten years now, my publishing costs continue
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We ship the FI book
inside Australia COD Australia Post. When the order arrives at your post office
you pay the postman and he sends the money to us. Outside Australia we require a
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