75
InstructIon Manual
Detailed maintenance
WARNING:
Discs get hot with use. To avoid injury, take care not to contact with hands or
legs.
WARNING:
Disc brakes require initial wearing in to function correctly.
Ride gently for several kilometres before braking heavily in sudden, fast or downhill conditions.
Brake performance will change over the wear in period. Clean the brake disc before first ride using
methylated spirit. Never clean using oil or other lubricants.
3. loosen the cable adjuster screws on inside part of caliper, and check the gaps between the in-
ner and outer pads and the disc are suitable. Manually push the pads so they almost touch the disc,
and then retighten adjuster screws to 8-10nM.
4. Check the wheel runs freely when brake lever is released. If further adjustment is required,
turn the adjusting nut/screw accordingly, and tighten. Activate levers to check brakes are working
correctly.
To prevent adjustment screws from working loose, ensure internal Caliper fixing screw is tight
(4-6nm).
adjust or change brake pads
When brake force weakens, brake pads may be worn. adjustment can be actioned through steps 3
and 4 above. If pads require replacement, loosen internal caliper fixing screw, remove outer then
inner pad, and then repalce inner then outer pad. then follow the steps for installing the front
caliper above.
WARNING Discs get hot with use. To avoid injury, take care not to
contact with hands or legs.
WARNING Disc brakes require initial wearing in to function correctly.
Ride gently for several kilometres before braking heavily in sudden, fast or
downhill conditions. Brake performance will change over the wear in period.
Clean the brake disc before first ride using methylated spirit. Never clean
using oil or other lubricants.
PBLF/0
9
PACIFIC BRANDS SPORT & LEISURE PTY LTD ABN 53 098 742 708
60
Tread Worn Off
Worn out Brake Shoe (Replace)
Usable Brake Shoe
Brake shoes must have adequate usable tread.
Tread
Disc
Disc
Mounting
Bolts
Fork Drop
Out
Quick
Release
Lever
Fork Leg
Caliper
Mounting
Bolts with
Spacers
Brake
Cable
Housing
Hub
Actuating
Arm
Cable
Boot
with
spring
inside
Rotating
Rod
Caliper
Body
Cable
Anchor
Bolt
Centering
Bolt
Brake Shoe Replacement
Brake shoes must be replaced if worn so far that there is insufficient effective pad material remaining
or they are worn past the "wear line" indication.To replace, first remove the worn brake shoes after
disconnecting the holding mechanism.Depending on the type of brake,as described on previous pages,
the holding mechanism may be a hexagonal nut or an Allen screw arrangement, or a combination of
both.Take note of the order and position in which the various curved washers and spacers are attached.
Fix the new brake shoes, adjusting the angle and clearance to the rim as previously described, and
tighten firmly. It will usually be necessary to adjust the rim clearance after first loosening the control
cable anchor bolt, then screwing in cable adjusters and finally tensioning the cable. Be sure to re
fasten the anchor bolt after adjusting the cable. Always replace brakeshoes in pairs - never one side
only. Before riding test brakes to ensure they are effective.Worn out Brake Shoe (Replace) Usable Brake
Shoe Brake shoes must have adequate usable tread.
Disc Brakes
If your bike is fitted with disc brakes,the rear brake will be already attached.Check all components for
tightness and function before riding.
Installing the front disc
When installing the front disc to the hub,ensure the arrows on the disc are pointing in the direction of
forward wheel rotation.Tighten the disc to hub with the M5 screws disc mounting bolts,in a star pattern
sequence,using torque of 5-8 NM.
Installing the front caliper
1.Install caliper on front fork lugs,and tighten front fork M6 screws to torque 8-10NM.
2.Thread the inner brake cable through the top cable adjuster on the caliper,and then through the
actuating arm , tightening the cable anchor bolt to torque 6-8NM to secure firmly.
3.Loosen the cable adjuster screws on inside part of caliper,and check the gaps between the inner and
outer pads and the disc are suitable.Manually push the pads so they almost touch the disc,and then
retighten adjuster screws to 8-10NM
4.Check the wheel runs freely when brake lever is released.If further adjustment is required,turn the
adjusting nut/screw accordingly,and tighten.Activate levers to check brakes are working correctly.
To prevent adjustment screws from working loose,ensure Internal Caliper fixing screw is tight(4-6nm).
Adjust or Change brake pads
When brake force weakens,brake pads may be worn.Adjustment can be actioned through steps 3 and
4 above.If pads require replacement,loosen internal caliper fixing screw,remove outer then inner pad,
and then replace inner then outer pad.Then follow the steps for Installing the front caliper above.
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