Manufacturers of Transmission & Precision Engineering Components

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SHIVAM AUTOTECH LIMITED

A HERO GROUP COMPANY

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Overview

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Manufacturing Locations

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Customers

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 Combined Braking System
• Combined Braking System (CBS) made compulsory by Government of
India on all 2-wheelers < 125 cc, from April 2019

• Safety feature enabling activation of both front and rear brakes on

pressing rear brake foot pedal

• Shivam is the current supplier of CBS to Hero Motocorp

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 German-Tech Braking System
• Proprietary CBS launched in the after market for all Hero and Honda
motorcycles < 125 cc, having drum brakes on both wheels, manufactured
before April 2019.
• Designed to be retrofitted onto the old vehicle with minimal changes to
the bike, distributes braking force to both wheels in appropriate ratio
• Advantages –
• Stable braking
• Reduced possibility of fish tailing under hard braking
• Reduced stopping distance
• Tested as per Indian Standard IS.14664.2010
• Vehicle – 2 year old 100 cc motorcycle
• Stopping Distance reduced by approx. 20 %

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GERMAN-TECH BRAKING SYSTEM

INSTALLATION

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 Contents

• Packaging
• Pre-Installation Checks
• Rear End Fitment
• Front End Fitment
• Post-Installation Checks

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Packaging

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 Pre-Installation Checks (1/3)
Ensure correct variant of GBS Assembly
• Ensure the inventory of following items in the packaging :

Front Brake Arm

Quantity – 1
GBS Control Box Mechanism Sub-Assembly Brake Cable
Quantity – 1 Quantity – 1

Split Pin
Quantity – 1
Cable Channel Long Nut Cable Dowel C Pin
Quantity – 1 Quantity – 2 Quantity – 2 Quantity – 1

Instruction Manual
Quantity – 1
M8 Flange Nut M8 Allen Head Bolt
Quantity – 1 Quantity – 1 10

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 Pre-Installation Checks (2/3)
Check wear on both front and rear brake shoes
Rear Brake Shoes Front Brake Shoes
• Press the foot brake pedal to its extreme • Press the right hand brake lever to its extreme
position position

• Visually observe the rear brake panel for the 2 • Visually observe the rear brake panel for the 2
arrow marks – one on the brake panel, and the arrow marks – one on the brake panel, and the
other on the brake cam. other on the brake cam.

• If both arrow marks match or close to match, as shown in the image, then the brake shoe is
completely worn out, and requires replacement.
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Pre-Installation Checks (3/3)
Visually check the condition of following parts and check for any
cracks or breakage or irreparable wear –

Foot Brake Pedal Rear Brake Arm Rear Brake Cam

Front Brake Cam Rear Tyre

Front Tyre

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Rear End Fitments (1/4)
Dis-assemble silencer from motorcycle

Remove 2 nos nut from the

engine exhaust connection point

Place the bike on main stand Disassemble the silencer

Remove 1 nos nut and bolt + washer

from frame connection point

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 Rear End Fitments (2/4)
Dis-assemble brake rod from motorcycle

Remove the adjusting nut completely Press the brake foot pedal Remove the brake rod from
rear wheel connection

Remove the brake rod Remove the split pin and C Pin

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 Rear End Fitments (3/4)
Dis-assemble Torque Link from motorcycle

Dis-assemble the torque link from rear brake end fixing point Dis-assemble the torque link from frame fixing point

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 Rear End Fitments (4/4)
Assembly of GBS Control Box Mechanism Sub-Assembly onto the bike

Assemble the GBS Control Box Assemble GBS pedal rod to the Assemble GBS brake rod to rear
Sub-Assy to the bike foot brake pedal brake arm

Assemble brake cable casting end

Route the cable through frame, all Pull the cable and route it through
to GBS Lever, in the slot
the way to the front end the slot in control box

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 Front End Fitments

Remove the front cable Pull the front brake arm out Mount the GBS Front Brake Arm
connection from front brake arm

Top Slot

Bottom Slot

Install Cable Channel to Front

Pass both brake cables (GBS brake cable through Brake Panel
top slot, and front brake cable through bottom slot)
through the dowel and tighten long nut

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 Post-Fitment Checks

• With bike on main stand, move the rear wheel by hand, and check if the
wheel gets stopped on pressing the foot pedal.
• Subsequently, ground the rear wheel, and move the front wheel by hand.
The wheel should get stopped on pressing the foot pedal.

Adjust front free play by loosening or tightening Adjust rear free play by loosening or tightening
the long nut on front brake cable the adjusting nut on GBS brake rod

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Thank You!
Shivam Autotech Limited
10, 1st Floor, Tower A, Emaar Digital Greens,
Sector - 61, Golf Course Extension Road,
Gurugram, Haryana – 122102
CIN: L34300HR2005PLC081531

E-mail : info@shivamautotech.com
Web Site : www.shivamautotech.com

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