1. Verify Proper Drum and Shoe Installation:
* Double-check everything: Before even attempting adjustments, confirm you correctly installed the new rear brake shoes, springs, and other components. A single incorrectly installed part can severely hamper braking performance. Refer to a repair manual for your specific year ZX2 for precise installation instructions. Incorrect installation is the most likely culprit.
* Shoe wear: Even new shoes can have uneven wear if the drums weren't properly surfaced (turned on a lathe) during the replacement process. Uneven wear will cause inconsistent braking.
2. Adjust the Emergency Brake Cables:
The ZX2's emergency brake uses cables that need adjusting to properly engage the rear brake shoes. There are typically two adjustment points:
* At the rear brakes: Look for a small star wheel adjuster on each rear brake backing plate. You'll need a small screwdriver or similar tool. With the emergency brake released, turn the star wheel clockwise to tighten the cable and increase the brake's grip. Do this slowly and test the emergency brake after each small adjustment. Over-tightening can lead to dragging brakes or damage.
* At the cable equalizer: The cables run from the handle to the rear brakes and often connect at an equalizer. This equalizer might also have an adjustment point. Consult a repair manual to locate this and adjust if necessary. You might need to loosen the equalizer's nut and then rotate it to adjust the cables.
3. Other Potential Problems:
If adjusting the cables doesn't solve the problem, consider these possibilities:
* Broken or stretched emergency brake cable: A worn or broken cable will prevent proper engagement. Inspect the cables for any visible damage. Replacement might be necessary.
* Seized Brake Mechanisms: The rear brake mechanisms (parts within the brake drum) could be seized or rusty. This is less likely if you've just replaced the parts, but worth checking.
* Low Brake Fluid: While primarily impacting the service brakes, very low brake fluid can also affect emergency brakes, although it's less likely to be the sole cause. Check your brake fluid level.
* Incorrectly Adjusted Service Brakes: While unlikely to fully prevent the e-brake from working, severely adjusted service brakes could make the e-brake feel weak or ineffective.
Important Considerations:
* Repair Manual: A repair manual specific to your year and model ZX2 is highly recommended. It will provide detailed diagrams, torque specifications, and adjustment procedures.
* Safety: Always work in a safe and well-ventilated area. Block the wheels to prevent the vehicle from rolling.
* Professional Help: If you're uncomfortable performing these adjustments or if the problem persists after trying these steps, it's best to take your ZX2 to a qualified mechanic. Improper brake adjustments can be dangerous.
By systematically checking each step and using a repair manual, you should be able to identify and resolve the emergency brake issue. Remember to test the emergency brake frequently throughout the adjustment process.
