Ultra motor A2B Metro, Service Manual

Page: 21 / 48

3-3
BRAKES
11. Pull in and hold the brake lever. Check
that the rotor is still centered within the
caliper body.
12. Pull in and hold the brake lever. Torque
the CPS bolts (B,
Figure 3 ) to the specifica-
tion in Table 5 while holding the brake lever
in.
13. Release the brake lever, and spin the
wheel. Listen for the sound of the inboard
pad rubbing against the brake disc.
14. If rubbing is noted, turn the inboard
pad adjuster counterclockwise (out from
the caliper) two or three clicks, and
recheck.
15. Repeat Steps 13 and 14 as needed.
16. Trim the inner wire end so its end
extends no more than 20 mm (3/4 in.)
beyond the anchor. Crimp a new cable
ferrule onto the cable end.
17. Use the barrel adjuster (B,
Figure 1 ) at
the brake lever to remove any cable slack.
Turn the adjuster outward until brake lever
freeplay is eliminated. However, do not go
so far that the caliper torque arm is moved.
Make sure the caliper torque arm is com-
pletely released, and tighten the adjuster
locknut (A) against the brake lever hous-
ing.
BRAKE CALIPER
Removal
The following procedure shows the remov-
al of a front caliper. This procedure also
applies to a rear caliper.
1. If the caliper is being replaced, perform
the following:
a. Clip the cable ferrule from the brake
cable inner wire.
b. Turn out the anchor bolt (A,
Figure 3
),
and release the inner wire from the pinch
mechanism.
c. Pull the cable housing and inner wire
from the caliper barrel adjuster.
2. Remove the caliper mounting bolts (A,
Figure 5
), and slide the brake caliper (B)
from the brake disc.
Installation
A fourth-hand tool (Park Took BT-2) is
needed for this procedure.
1. Apply oil to the inside of the cable hous-
ing.
2. Insert the inner wire through the brake-
lever end of the cable housing until the
wire emerges from the caliper end of the
housing.
3. Press the brake lever toward the handle-
bar, and connect the inner wire end (B,
Figure 2
) to the anchor (A) on the brake
lever.
4. Pull the cable housing, and slide the
cable inner wire (C,
Figure 1 ) through the
slots in the brake lever, adjuster barrel (B)
and locknut (A). Seat the cable housing
ferrule into the adjuster barrel.
5. At the caliper, turn the barrel adjust all
the way into the caliper.
6. Feed the inner wire through the caliper
barrel adjuster, and seat the cable housing
in the adjuster.
7. Route the inner cable through the pinch
mechanism on the caliper.
8. Use the fourth-hand tool to remove the
slack from the cable, and torque the brake
caliper anchor bolt (A,
Figure 3 ) to the
specification in Table 5.
9. Loosen the CPS bolts (B,
Figure 3 ) so the
caliper can move freely.
10. Turn the inboard pad adjuster (C,
Figure
3 ) clockwise (inward toward the caliper)
until the brake disc (A, Figure 4 ) is centered
within the caliper body (B). The caliper is
properly adjusted if the space on each
side of the brake disc is the same.
Brake Pa
d Rotor
Caliper
FIG. 4
A
B