Brakes

Submitted by xjcdadmin on Tue, 06/25/2013 - 15:02
Model(s)

Front brake adjustment

The brake can be adjusted by simply adjusting the free play of the brake lever. The piston in the caliper moves forward as the brake pad wears out, automatically adjusting the clearance between the brake pads and brake disc.

CAUTION: Proper lever free play is essential to avoid excessive brake drag.

The free play at the end of the front brake lever should be 5 — 8 mm (0.2 0.3 in).

1.      Loosen the lock nut.

2.      Turn the adjuster so that the brake lever movement at the lever end is 5 - 8 mm (0.2 - 0.3 in) before the adjuster contacts the master cylinder piston.

3.      After adjusting, tighten the lock nut

WARNING: Check the brake lever free play. Be sure the brake is working properly.

1 Adjuster 2. Lock nut a. 5 — 8 mm (0.2 — 0.3 in)

Rear brake pedal position adjustment

The brake pedal top end should be 27 - 33 mm (1.1 - 1.3 in) below the top of the footrest.

1.      Remove the brake pedal pinch bolt and remove the brake pedal.

2.      The punched mark on the brake pedal shaft and the punched mark on the brake pedal which must be aligned to install the brake pedal.

3.      Install the brake pedal pinch bolt securely.

1. Pinch bolt 2 Punched marks a. 27 — 33 mm (1.1 —1.3 in)

Rear brake adjustment

The brake pedal free play is set at the factory. This free play ranges from where the brake pedal is trod to where the brake begins to take effect. No adjustment is necessary.

Free play: 20 - 30 mm (0.8 — 1.2 in)

a. 20 - 30 mm {0.8 -1.2 in)

Front and rear brake pad check

A wear indicator is attached to each brake pad to facilitate disc brake pad checks. This indicator permits a visual check without disassembling the pads. To check, look at the pad wear indicator in back of the caliper. If any pad is worn to the wear limit, replace both pads in the caliper.

FRONT

1. Wear indicator

REAR

1 Wear indicator

Inspecting the brake fluid level

Insufficient brake fluid may allow air to enter the brake system, possibly causing the brake to become ineffective. Check the brake fluid level and replenish when necessary observing these precautions:

FRONT

1. Lower level

REAR

1. Lower level

1. Use only the designated quality brake fluid; otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

Recommended brake fluid: DOT #3

2.      Refill with the same type and brand of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.

3.      Be careful that water or other contamination does not enter the master cylinder when refilling. Water will significantly lower the boiling point and may result in vapor lock.

4.      Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

Brake fluid replacement

1.      Complete fluid replacement should be done whenever the caliper cylinder or master cylinder is disassembled, or the fluid becomes seriously contaminated.

2.      Replace the following components whenever damaged or leaking.

a.    Replace all brake seals every two years.

b.    Replace all brake hoses every four years.

c.    Replace the plunger kits every two years.

Brake light switch adjustment

The brake light switch is operated by movement of the brake pedal. To adjust, hold the main body of the switch with your hand so it does not rotate and turn the adjusting nut. Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect.

1. Main body 2. Adjusting nut