WHEEL BRAKE ASSEMBLIES
Brake Cable Removal and Installation
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 6-11
6
For Vehicles with Clip:
8. Locate the brake cable hanger clip (1), if equipped, on the frame and remove it from the vehicle
(Figure 6-20, Page 6-12)
. Discard the clip.
9. Remove the forward leaf spring mounting bolt (3/8-16 x 3-3/8-inch) (5) and 3/8-16 nylon locknut (6). Dis-
card the mounting bolt.
For Vehicles with P-Clamp:
10. Remove the 3/8-16 nylon locknut (6) and p-clamp (2) that secure the brake cable (3) to the frame.
11. If replacing brake cable, remove the p-clamp (2) from the brake cable (3) and retain for installation of new
cable.
For All Vehicles:
12. Note routing of cable through hanger for installation of new cable. Pull cable from vehicle.
Brake Cable Installation
1. Place the end of the new cable into the equalizer (4)
(Figure 6-18, Page 6-10)
. Secure the cable to the
vehicle frame with new E-clip. Route cable through hanger in the same manner as before.
2. At the rear wheel brake, connect the cable to the brake actuator arm using new clevis pin (2) and new
bow-tie pin (1)
(Figure 6-19, Page 6-10)
.
3. Place the cable in the cable support bracket (5) and secure with new E-clip (3).
For Vehicles Originally Equipped With Clip:
4. Insert a new 3/8-16 x 3-1/2-inch hex-head bolt (5) through the leaf spring mount and leaf spring
(Figure 6-20, Page 6-12)
.
For All Vehicles:
5. Install the brake cable p-clamp (2) over the smaller diameter portion of the brake cable (3) so that the flat
face of the p-clamp is oriented to the inboard side of the leaf spring mount (4) on the frame.
6. Secure the brake cable p-clamp (2) to the leaf spring mounting bolt (5) finger-tight with the 3/8-16 nylon
locknut (6).
See following NOTE
.
NOTE:
Make sure there is a 1/8-3/16-inch clearance between the tire and the brake cable. If clearance is
not adequate, slide the brake cable forward inside the p-clamp until the correct clearance is
obtained.
7. Tighten the locknut (6) to 15 ft-lb (20.3 N·m). Do not allow the p-clamp to rotate while tightening the hard-
ware.
8. Adjust the brakes.
See Brake Adjustment on page 6-8.
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