Rear Disk Brake Issues - Resolved

Finally, the rear disk brake issue has been resolved. Khivraj Service Bangalore received a new brake kit from Pune. The new kit is of the same make (KBX, Kalyani). The rear disk looks different, and it does not have a grove ring the previous one had. Also the ventilation holes pattern is same as the front disk. The old kit was removed after taking off the side panels. The rear wheel had to be taken off to replace the disk.

On the first run after the new kit was installed, the brakes did not work well even after pressing the brake lever down hard. And the disk got very very hot. The engineers then took the bike in again, and did rear wheel alignment. The logic here was that if the wheel is not aligned correctly, the disk (which is mounted directly on the wheel) would cause excessive friction with the brake pads, which are mounted separately. This idea worked, and on the 2nd run, the brakes worked perfectly.

I did another 150Km, a wet ride to Nandi Hills on the next day, and the rear brakes work like a charm. My only complaint is that the disk pad assembly is not covered from the top. That may allow guk and mud to go in and damage the assembly. Not sure why Bajaj did not put a simple rubber cap to cover it.

Thanks to prompt Bajaj service, for resolving this brake issue.