Unsure how to go about installing new master cylinder and brake caliper.

[DuckSoup]

Hey guys,

So I'm in a bit of a pickle right now. For my DIY go-kart I decided to pick up a single hydraulic brake setup. The go-kart already had an 8-in brake rotor that's 3mm in thickness.

I went through Go powered sports to pick up the new brake system and it came with a master cylinder and brake caliper with brake pads installed.

My first question is how I'm supposed to properly install the master cylinder? This setup came with no instructions and the research I found online have all had various other kinds of master cylinders not exactly like this one.

I'm assuming the two holes in the picture are where I would maybe mount this on the go-kart frame?

But this little gold metal piece is also confusing as it looks like it also attaches to those two metal holes. Am I somehow supposed to attach that to my brake pedal or brake rod? Not sure how that's supposed to work if it's also mounting to the frame.

One other issue I'm having is with the brake caliper. They seem to be brushing up against the rotor even when not engaged. Is it possible the rotor at 3 mm is just too thick?

I'm just having trouble finding good resources on how to properly install this so I'm at a loss at the moment. Any guidance you guys could provide would be really helpful.

 

[Hellion]

Your pics....

Hydraulic brake calipers can be in any "state" when they are shipped; the pads can be closed or pushed together or they can be apart with the piston fully retracted in the housing. Stick a Philips flat head screwdriver or a putty knife between the brake pads and see if you can push them apart and depress the piston.

Looks like the 'rainbow' zinc plated 'L' shaped bracket is what is welded to the frame and the master cylinder is bolted to it.

They seem to be brushing up against the rotor even when not engaged.

Designed that way. "They" (the brake pads) should be in constant contact with the rotor at all times. Brake pads lightly drag on disc brake rotors but do not impart much actual friction unless you stomp on the pedal, just like your father's Oldsmobile (now defunct, sadly).

 

[DuckSoup]

Your pics....

Hydraulic brake calipers can be in any "state" when they are shipped; the pads can be closed or pushed together or they can be apart with the piston fully retracted in the housing. Stick a Philips head screwdriver between the brake pads and see if you can push them apart and depress the piston.

Looks like the 'rainbow' zinc plated 'L' shaped bracket is what is welded to the frame and the master cylinder is bolted to it.



Designed that way. "They" (the brake pads) should be in constant contact with the rotor at all times. Brake pads lightly drag on disc brake rotors but do not impart much actual friction unless you stomp on the pedal, just like your father's Oldsmobile (now defunct, sadly).

Thank you for the input.

So if I mount that zinc plated part to the frame and then attached the master cylinder to it, how exactly do I mount the brake pedals to the master cylinder? In that one picture all I have currently is just that long rod but is there a better way to attach the two?

It looks like that zinc plate goes over the part that presses on the master cylinder.

 

[Master Hack]

brake pedals to the master cylinder? In that one picture all I have currently is just that long rod but is there a better way to attach the two?

The yoke on the end of the rod is broken.

 

[Hellion]

On the movable part of the master cylinder, is that a threaded rod? You could screw on a clevis fork there if it is threaded, but obviously you need some kind of rod linkage and a pedal pivot

 

[DuckSoup]

The yoke on the end of the rod is broken.

Oh good catch, I didn't know what that was supposed to be for.

Okay I have a little bit of research to do to figure out how I'm going to get that all connected but it sounds like I have a decent idea how to mount the master cylinder. I'll take some pictures once I have it set up just to make sure I'm doing it right.

Appreciate the feedback.

 

[Master Hack]

Maybe this helps

Basic Brake System Operation

A basic overview of the vehicle's braking system (with diagram), and a description of each of its major components. Being able to stop the vehicle is more important than its acceleration!

www.undergroundautomotive.com

 

[DuckSoup]

Maybe this helps

Basic Brake System Operation

A basic overview of the vehicle's braking system (with diagram), and a description of each of its major components. Being able to stop the vehicle is more important than its acceleration!

www.undergroundautomotive.com

That does help, thank you.

A lot of the replies here helped a bunch and I think I know what I need to do.

I need to mount the master cylinder behind the brake pedal and attach to it with a threaded rod and some fork clevises. I'm just having trouble finding the parts locally.

Just trying to figure out all the pieces I need to make it happen.

 

[Hellion]

Clevis, yoke, same thing.

… I'm just having trouble finding the parts locally.

That is the way of things now. Unless you know a store has what you need, like you’re familiar with the store and their stock, it’s not worth the shoe leather trundling all over town hoping you’ll find what you need. Sadly online shopping is the way. However, I have had the best luck finding oddball hardware bits and parts at farm stores, Tractor Supply in general and Rural King in particular.

I am so far not impressed with this hydraulic disc brake kit. No instructions, for one, but that mounting bracket doesn’t appear to have enough meat for welding it on and has no facility for a bolt-on arrangement either. That is merely my first impression. If you want, you can ditch it and go for a mechanical disc brake. They just always work.