E-Z-GO RXV GASOLINE, Service & Repair Manual

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Page M-4
MECHANICAL BRAKES
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
B
I
Fig. 4 Checking for Excessive Free Travel
The correct brake pedal free travel setting should be set
to 3/4" (1.9 cm) (Ref. Fig. 4).
Adjust brake pedal free travel as described in ‘MAINTE-
NANCE AND REPAIRS’ if required.
4. Inspect the brake cables.
Inspect for damage to the outer cable, fraying of the
inner cable or lack of free motion when the pedal is
applied and released. Inspect the brake cable sup-
ports to be sure the cables are properly secured. If
any of these conditions are found, replace both cables
and equalizer as a set.
5. Check the clevis pins.
Check clevis pin and snap ring attaching the brake
cables to the brake levers. They must be loose when
the brake pedal has been released . If the clevis pins
are not loose, but brake pedal free travel is correctly
adjusted and the brake cables move freely, the prob-
lem is likely in the wheel brake.
6. Inspect the brake cable equalizer linkage.
Inspect for signs of corrosion, damage, wear or exces-
sive misalignment . Replace if corrosion, damage, or
wear is found.
7. Inspect parking brake pedal hinge.
Check for broken or rusted springs. and correct reten-
tion of the hinge pin. Operate parking brake pedal to
confirm smooth operation of the hinge mechanism
8. Check the condition and operation of the parking
brake latching mechanism.
The parking brake should latch firmly and release as
soon as the accelerator pedal is depressed.
9. Inspect the parking brake kick-off cam.
Look for wear and for correct adjustment. With the
parking brake engaged and fully latched, there must
be no
10. Inspect kick-off cam linkage and bushings.
Check for wear and damage. The kick-off cam pivot
and bushings should move freely and be free of corro-
sion. The kick-off cam should rotate when the acceler-
ator pedal is depressed.
Periodic Brake Performance Test (PBPT)
To prevent severe injury or death resulting
from operating a vehicle with improperly oper-
ating brake system, the braking system must
be properly maintained. All driving brake tests
must be done in a safe location with regard for
the safety of all personnel.
The Periodic Brake Performance Test (PBPT) should be
performed regularly (see Periodic Service Schedule in
the GENERAL INFORMATION AND ROUTINE MAIN-
TENANCE section of this manual) as an evaluation of
braking system performance. It is useful as a method of
identifying subtle loss of performance over time and as
part of troubleshooting a problem vehicle.
Before performing this test, inspect the brake pedal and
linkage and correct any problems found including adjust-
ing the brake pedal free travel if required.
The purpose of this test is to compare the braking per-
formance of the vehicle to the braking performance of
new or “known to be good” vehicles or to an established
acceptable stopping distance (see below). Actual stop-
ping distances will be influenced by weather conditions,
terrain, road surface condition, actual vehicle weight
(accessories installed) and vehicle speed. No specific
braking distance can be reliably specified. The test is
conducted by latching the parking brake to eliminate dif-
ferent pedal pressures and to include the affects of link-
age mis-adjustment. Significant changes or differences
in braking performance will be evident due to mis-adjust-
ment.
Establish the acceptable stopping distance by testing a
new or “known to be good” vehicle and recording the
1 2
3 4
5 6
7 8
9 10
11 12
3/4” (19.05 mm)
To Measure and Correct Brake Pedal Free Travel:
1. Release Parking Brake
2. Hold a 12” ruler perpendicular with the floor mat
and close enough to the pedal to take a reading.
3. Free travel distance should be around 3/4 inch.
4. Adjust Brake Cable Bracket hardware to allow for
correct Free Travel Distance.