BRAKE DISC

USER MANUAL

AWARDS:
CONTENTS

Introduction

Safety Precaution

Front Brake Disc

Remove The Front Wheel
Release The Old Brake Disc
Fit The Front Brake Disc
Refit The Front Wheel

Rear Brake Disc

Remove The Rear Wheel
Fit The Rear Brake Disc
Refit The Rear Wheel

Inspection & Maintanance

Model Information
INTRODUCTION

Meng Kah Auto Parts Trading Sdn. Bhd. incorporated in the year 1998, with
the core business of importing and distributing motorcycle parts and
accessories. With a successful venture, it has created a brand "Racing Boy" to
meet the high demand and expectation of its customers. The services
include in-house designing, testing, developing and manufacturing of high
quality and stylish products.

In the year 2013, Racing Boy has again rebranded itself as "RCB" to further
solidify as an international name. Today, RCB design and manufacture a full
range of accessories that includes rims, absorbers, braking systems, engine
parts and handling systems. RCB, a leading international brand.
SAFETY PRECAUTION

Safety Symbols
In this manual, mounting intructions and other technical documents, important information
concerning safety is distinguished by the following symbols :
Danger!
The Danger Symbol: If not observed, have a high degree of probability that they will cause
serious injury or even death.

Warning!
The Warninng Symbol: If not observed, could possibly cause injury.

Caution!
The Caution Symbol: if not observed, could result in damage to the vehicle

This RCB product has been designed to comply with applicable safety standards. Products are not intended
to be used differently from the specific use for which they have been designed and manufactured. Use for
any other purpose, or any modification to, or tampering with, the Product can affect the performance of the
Product and may render the Product unsafe. Such modification or improper use will void the Limited
Warranty, and may subject the individual so using the Product to liability for bodily injury or property
damage to others.

Danger!
This Product is vital to the safe operation of the vehicle on which it is installed, and it is intended to be
installed only by a skilled, qualified individual who has been trained and/ or is experienced in the
installation and use for which the Product is intended. The installer must be equipped with the proper
tools of his trade, and with the knowledge and experience to deal with vehicle repairs. Improper or
incorrect installation, whether caused by a failure to faithfully and completely follow these Instructions
or otherwise, will void the Limited Warranty and could subject the installer to liability in the event of
personal injury or property damage. RCB shall not be liable for any damage or injury caused to or by
any person operating a vehicle on which a replacement product has been improperly installed.

The used product replaced by this Product must not be installed on any other product. Property
damage and personal injury, including death, could result.

Warning!
In this course of replacing the product, and related items such as brake fluid, brake pads, brake shoes,
and the like, the installer will be exposed to fluids and parts that may be deemed to be “hazardous
waste” under applicable laws, rules and regulations. All such wastes must be handled, recycled and or
disposed of in accordance with all applicable laws, rules and regulations. The failure to do so can
subject the generator of the hazardous waste to penalties under environmental laws, and could result
in bodily injury or property damage to the generator or others.

Always check that the brake fluid level in the reservoir is between the minimum and maximum levels
indicated on the reservoir. An incorrect level can cause brake fluid leaks or reduced brake system
efficiency. Too much or too little brake fluid in the reservoir could cause the brakes not to perform
properly, and personal injury, including death, could result.
SAFETY PRECAUTION

Warning!
To avoid creating a defective installation, avoid sharply striking and/ or damaging the Product, its parts
and its components, as this can impair their efficiency and may cause them to malfunction. If necessary,
replace any damaged part or component.

To avoid injury:
• Always wear gloves during disassembly and assembly of components with sharp edges.
• Do not allow skin surfaces to make direct contact between the pad and shoe linings since this
could cause abrasions.
• Ensure correct connection of any electrical contacts, checking that the warning lights come on.
If they do not, non-operation of the warning lights can cause a reduction in efficiency of the
braking system, or brake signaling failure.

Avoid contact of grease and other lubricants with the braking surfaces of the disc and pads as this could
affect the efficiency of the braking system and cause serious physical damage.

Caution!
Check that the bearing seats are free from dirt. Any dirt present can damage the seats during assembly
operations and shorten bearing life.

Do not use sharp tools when fitting rubber components, since this can damage them. Be sure to replace
damaged components.

Every time the discs are changed you should also replace the pads.

Notice
This feature only available for a certain model of motorcycle.
FRONT BRAKE DISC

REMOVE THE FRONT WHEEL

Notice
• Keep any type of magnets (including magnetic
pick-up tools, magnetic screwdrivers, etc.) away
from the front wheel sensor or front wheel sensor
rotor; otherwise, the sensor or rotor may be
damaged, resulting in improper performance of
the ABS system.
• Do not drop the front wheel sensor rotor or subject
it to shocks.
• If any solvent gets on the front wheel sensor rotor,
wipe it off immediately.

• First jack up your motorcycle securely in order to • Unscrew the nut on the pin and loosen the screws
unload the wheel. of the fork joint feet, on both sides if present,
Warning! without taking them out.
• Remove the pin keeping the wheel slightly raised
Securely support the vehicle so that there is no to permit extraction of the pin.
danger of it falling over.
• Remove the wheel.

RELEASE THE OLD BRAKE DISC

• Loosen the fastening screws of the caliper.

• Move the calliper away from the disc.
• Hook the caliper or calipers to the vehicle chassis by means • Rest the wheel on a rest surface.
of appropriate supports. • Unscrew and remove the disc fastening screws.
• Remove the disc to be replaced.
Warning! • Clean the area where the disc rests on the wheel
During all the operations described below, the caliper using a degreasing product.
fluid inlet hose must NOT be disconnected.
Warning!
Caution! Ensure that the solvent does not come into contact
Do not apply the brake lever when removing the with parts of the wheel that could be damaged
brake caliper. (rubber and paint). Absorb with paper.
FRONT BRAKE DISC

FIT THE FRONT BRAKE DISC

• Fit the new brake disc.

• Use torque wrench to tighten the fastening
bolts to the torque specified by the vehicle
manufacturer, in diagonally opposite sequence.

Warning!
Always replace badly corroded or damaged fastening
bolts with new ones. • Install the front caliper to the fork joint.
• Compress the suspension to bed the fork joint.
• Tighten the screws of the fork joint foots using
REFIT THE FRONT WHEEL
a torque wrench, applying the torque prescribed
by vehicle manufacturer.

• Insert the wheel in the fork joint observing the

forward rotation direction indicated on the wheel.
• Clean with a damp cloth and lubricate the surface
of the pin to facilitate insertion.
• Insert the pin keeping the wheel in the correct
position with one hand and centring the spacer
and the milometer transmission, if provided.
• Position the screws of the feet of the fork joint,
on both sides if present, only tightening them far
enough to keep them in position.
• Tighten the nut on the pin to torque prescribed
by the vehicle manufacturer.
REAR BRAKE DISC

REMOVE THE REAR WHEEL FITT THE REAR BRAKE DISC

Notice • Clean the supporting surfaces, all the seats and all
the components involved in the refitting operation
• Keep any type of magnets (including magnetic using a degreasing product.
pick-up tools, magnetic screwdrivers, etc.) away
from the front wheel sensor or front wheel sensor Warning!
rotor; otherwise, the sensor or rotor may be
damaged, resulting in improper performance of Ensure that the solvent does not come into contact
the ABS system. with parts of the wheel that could be damaged
• Do not drop the rear wheel sensor rotor or subject (rubber and paint). Absorb with paper.
it to shocks.
• If any solvent gets on the rear wheel sensor rotor,
wipe it off immediately.

• Stand the vehicle on a level surface.

Warning!
Securely support the vehicle so that there is no
danger of it falling over.
• Position the sprocket on the rear wheel.
TIP • Re-tighten the sprocket fastening screws, if
Place the vehicle on a center stand so that the provided, applying the tightening toque
rear wheel is elevated. prescribed by the vehicle manufacturer.

• Position the brake disc to the rim.

• Unscrew the nut on the pin. • Insert the new fastening screws and tighten them
• Remove nut and washer. with a torque wrench.
• Remove the pin keeping the wheel slightly raised
to permit extraction of the pin.
• Remove the spacer.
• Gently push the wheel towards the vehicle.
• Slide the chain out of the sprocket resting it on
its side.
• Remove the wheel.
• Release the old brake disc. Refer to “Front Brake
Disc” on page 5
REAR WHEEL

REFIT THE REAR WHEEL

• Slightly lubricate the surface of the pin to facilitate • Reposition the caliper on the brake disc.
insertion. • If the pads obstruct insertion of the caliper on the
• Insert the wheel into the fork. disc, press firmly with your hands on the pads to
• Reposition the caliper on the brake disc. retract the pistons.
• Gently push the wheel towards the vehicle. • Tighten the fastening screws of the caliper of
• Reposition the chain on the sprocket . calipers, applying the tightening torque
• Correctly reposition the spacer. prescribed by the vehicle manufacturer.
• Insert the pin, checking that it fits into the hole • Check the brake fluid level and top up if necessary
provided on the caliper supporting bracket and with new fluid in compliance with the
that the caliper is correctly positioned in its seat recommendations of the vehicle manufacturer.
on the fork. • Remove the vehicle from the stands.
• Check correct positioning of the pin in its seat on • Repeatedly operate the brake lever/ pedal until the
the fork. normal resistance has been restored and check
• Correctly reposition the washer and nut. braking efficiency.
• Position a shim (e.g. a screwdriver) between the
chain and the sprocket.
• Rotate the wheel far enough to block the shim
between the chain and the sprocket.

Caution!
This operation eliminates the need to tension the
chain.
• Tighten the nut on the pin to tightening torque
prescribed by the vehicle manufacturer.
• Rotate the wheel in the opposite direction and
remove the shim.
• Check correct tensioning of the chain according to
the directions provided by the vehicle
INSPECTION & MAINTENANCE

CHECKING THE BRAKE DISC Measure The Brake Disc Thickness

• Measure the brake disc thickness at a few different

locations.
• Out of specification Replace.

Warning!

In order to achieve optimum braking performance

with a new brake disc, always replace the brake pads
at the same time.
Damage/galling Replace
While working on the brakes, make sure that no
Warning! grease, paste, brake fluid or other chemicals come
Never attempt to make any repairs to the disc. into contact with the surface of the brake pads.

Measure The Brake Disc Runout

• Place the vehicle on suitable stand to make sure

the wheel to be measured is elevated.
• Remove the brake caliper.
• Hold the dial gauge at a right angle against the
brake disc surface.
• Measure the runout 1.5mm (0.06in) below the
edge of the brake disc.
• Brake disc runout limit: 0.15mm (0.0059in)
• Out of specification replace the brake disc.
MODEL INFORMATION

S-SERIES ALLOY DISC

– Floating Brake Disc

– Alloy 7075 (Aircraft Grade)
– Enchance durability level
– Improve Safety & Performance
– Provide Effective Braking Power
– Anodised anti Rust
– Better Heat Dissipation

E-SERIES STEEL DISC

ENGI
NE
PA RTSERED

– High Quality Buttons

– Heat treated Stainess Steel
– Enchance durability level
– Improve Safety & Performance
295MM

– Provide Effective Braking Power

– Better Heat Dissipation
XX
XX
4Z
49
D0
01