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CHAPTER 6 BRAKES

SERVICE MANUAL

CHAPTER 6 BRAKES PAGE. 7-

2. Measure the disc thickness at 8 different points

around the pad contact surface using a 0-1"
micrometer and a dial indicator. Replace disc if
worn beyond service limit.

Brake Disc Thickness

New 0.150-0.164" (3.810 - 4.166 mm)
Service Limit 0.140" / 3.556 mm

Brake Disc Thickness Variance

Service Limit 0.002 " (0.051 mm)
difference between measurements

3. Mount dial indicator as shown to measure disc

runout on the dial indicator. Replace the disc if
runout exceeds specifications.

Brake Disc Runout
Service Limit 0.005" (0.127 mm)

REMOVAL/ REPLACEMENT

1. Removal caliper and hub. Apply heat to the hub

in the area of the brake disc mounting bolts to
soften the bolt locking agent.

2.  Remove bolts and disc.
3.  Clean mating surface of disc and hub.
4.  Install new disc on hub and tighten to specified.

CAUTION:

Always use new brake disc mounting bolts.

Front Brake Disc Mounting Bolt Torque :
18 ft. lbs. (25 Nm )

6.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION

CAUTION:

The caliper is a non-serviceable Component; it must
be replaced as an assembly.

NOTE:

If any special service needed, contact the

CUV manufacture via the agent for the parts and
special instruction.

REMOVAL

Summary of Contents for XY40EV

Page 1: ...XY40EV SERVICE MANUAL ...

Page 2: ...d significant changes in specifications or procedures will be forwarded to all authorized XINGYUN dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BE...

Page 3: ...ONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 Electrical CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Brakes Never run an engine in an enclosed area Carbon monoxide exhaust gas is ...

Page 4: ...n result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of UTV Never service when the engine is warm or hot Escaping steam from cooling system or hot oil from the machine can cause severe burns The engine must be cool before service Crate of the UTV and parts in the UTV maybe have sharp edge always pay atten...

Page 5: ...ORMATION The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each UTV model for spare parts information and service 1 1 IMPORTANT INFORMATION 1 2 V I N AND MOTOR SERIAL NUMBER 1 3 VEHICLE DIMENSIONS ...

Page 6: ...Other brands may be similar in function and appearance but inferior in quality LOCK WASHERS PLATES AND COTTER PINS Replace all lock washers plates and cotter pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer s marks or numbers are visible When install...

Page 7: ...ct the connector two or three 4 Pull the lead to check that it will not come off 5 If the terminal comes off bend up the pin and reinset the terminal into the connector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness Use ...

Page 8: ...TABLE METRIC TO IMP Known Multiplier Result Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb In lb ft lb In lb Weight kg g 2 205 0 03527 lb oz Distance km h km m m cm mm 0 6214 0 6214 3 281 1 094 0 3927 0 03927 mph mi ft yd in in Volume Capacity cc cm3 cc cm3 lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade...

Page 9: ...SERVICE MANUAL CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N AND MOTOR SERIAL NUMBER The vehicle identification number is stamped into the left side of the rear frame tube The motor serial number is stamped into left side of motor crankcase ...

Page 10: ...CHAPTER 1 GENERALINFORMATION SERVICE MANUAL CHAPTER 1 GENERAL PAGE 1 6 1 3 VEHICLE DIMENSIONS Note The on road equipments rear view mirror turn lights etc are not Standard Equipment for USA ...

Page 11: ...CHAPTER 1 GENERALINFORMATION SERVICE MANUAL CHAPTER 1 GENERAL PAGE 1 7 NOTES ...

Page 12: ...onents are explained in the following chart on the following pages NOTE Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16 km 10 miles per hour However keep in mind that if the vehicle isn t used for a long period of time the month maintenance intervals should be followed Vehicles subjected to severe use such as operation in wet or dusty...

Page 13: ...ielectric grease to socket when replaced Air Filter Main Element Weekly Weekly Inspect Replace if necessary Transmission Oil Level 20 hrs Monthly Inspect monthly change annually Battery Monthly Monthly Check clean Terminals Check damage and deformation D Brake pad wear 10 hrs Monthly Inspect periodically Rear Gear case Oil 100 hrs Monthly Check monthly and change annually General Lubrication 50 hr...

Page 14: ...intain level Between fill lines See 7 CONTROL As require change every two years or 200 hours 3 Transmission Oil SAE 80W 90GL5 Add to proper level on dipstick Change annually or at 100 hours Item Lube Rec Method Frequency 6 Steering system Grease Lubricate the pivoting and sliding parts Every 3 months or 50 hours 7 Tie rods Grease Grease Semi annually 8 Shift Linkages Grease Locate fittings and Gre...

Page 15: ...se M molybdenum disulfide MoS2 grease water resistant 4 When suspension action becomes stiff or after washing 5 Hours are based on 10 mph 16Km h average PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs ...

Page 16: ...s that have a cotter pin installed must be serviced by an authorized Dealer Rear Tapered nuts install with tapered side against wheel AXLE BOOTS Front Shaft Boots Rear Axle CV Joints Boots Check the protective boots for holes or tears If any damage is found have them replaced by an authorized dealer REAR SPRING ADJUSTMENT The rear shock absorber spring is adjusted by rotating the adjuster in the d...

Page 17: ...periodically for free operation steering should move freely through entire range of travel without binding Park on level ground Turn the steering wheel right and left Check for excessive free play abnormal noises or a rough feeling Have an authorized dealer repair as necessary for proper operation Lubricate the pivoting parts Recommended lubricant Lithium soap based grease CAMBER AND CASTER The ca...

Page 18: ... the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury The front brake is hydraulic disc brakes which is depressing the brake pedal These brakes are self adjusting and require no adjustment The following checks are recommended to keep the brake system in good operating condition How often they need checking d...

Page 19: ...e the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The brake fluid reservoir is located under the hood When checking the fluid level make sure the top of the brake fluid reservoir is level Use only the recommende...

Page 20: ... Lamp Replacement 1 Use bulb 12V 35W 35W 2 Pull the cable plug off the conducting strip in the socket remove the clip before dismounting the bulb 3 Fit a new bulb into the socket sitting properly in the three slots install the clip as shown in the fig and connect the cable plug to the conducting strip 4 Change the bulb Taillight Brake light Lamp Replacement If the taillight brake light does not wo...

Page 21: ... the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 8 71mm below the mark placed on the wall in step 2 NOTE Driving weight must be included on the seat 5 To turn the two adjusting screws clockwise is to lower the beam area and t...

Page 22: ...CHAPTER 3 ELECTRICAL 3 1 PARTS INSPECTION AND SERVICE 3 2 BATTERY 3 3 Drive System 3 4 Drive System Common Malfunction 3 5 LIGHTING SYSTEM 3 6 LCD Meter 3 7 WIRING DIAGR ...

Page 23: ...e vehicle on a level surface with the headlight approximately 33in 10m from a wall 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Start the engine and turn the headlight switch to high beam 5 Observe headlight aim The most intense part of the headlight beam should be aimed 86mm to 129mm below the mark placed on the wall in step...

Page 24: ... adjusting screws forward is to heighten the beam TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 From the rear of the taillight remove two screws holding lens cover in place and remove lens cover 2 Remove lamp and replace it with recommended lamp 3 Reinstall the lens cover removed in step 1 4 Test the taillight brake light ...

Page 25: ...mage the battery leakage of liquid and even explosion cause serious injury or death In order to avoid short circuit you need to be extra careful when you Install or remove batteries and using insulation tools The cable for connecting the battery cannot placed casually it may cause short circuit The battery terminal screws should be covered by insulating cap Arrangement of cable should void overlap...

Page 26: ...aintenance 3 avoid exposure in the sun The sun exposure will increase the temperature of the battery increase the amount of water loss thereby affecting the battery life 4 Electric vehicles should be slow to accelerate in the start If you step on the accelerator pedal to the end at first time it will cause the battery discharge is too fast thereby reduction of battery life 5 In winter the battery ...

Page 27: ...figuration Motor rated power 4KW Motor type BLDC Battery 12V100Ah 5 Maximum Speed 40km h Mileage 50km 3 3 1 Electronic shift lever Have 3 gears Front Neutral Reverse When select reverse reverse buzzer will be working Schematic Diagram ...

Page 28: ...al voltage 1V If the initial voltage 1V the motor cannot working You can use a multimeter to measure the voltage between Blue line and Yellow line which is the pedal output voltage 3 3 3 Motor controller 1 Controller Number 2 Power indicator light 3 Work indicator 4 Host computer interface Terminal function 1 2 3 4 ...

Page 29: ...celerator pedal OUTPUT A4 Ground enable B4 Reverse C4 Front B6 Motor speed signal A7 Hall sensor C B7 Hall sensor B C7 Hall sensor A A8 Hall sensor power supply B8 Motor temperature signal C8 Hall sensor power supply 3 3 4 Motor Rated voltage 60V TPYE BLDC Rated speed 3000rmp Rated torque 13N m 1 Controller Number 2 Power cable 2 1 ...

Page 30: ...abnormal check the car charger output voltage 60V if the voltage is normal battery is fault otherwise check the input power and charging line If the line and power supply is ok car charger is fault 3 4 Drive System Common Malfunction 3 4 1Vehicle without electricity check the fuse and fuse box check the wire which connect the 12V battery 3 4 2 Vehicle have electricity but motor not start Motor con...

Page 31: ...V 4 0V If the voltage is not normal check the accelerator pedal If the voltage between terminal B3 and A1 is normal controller fault Motor controller indicator is abnormal 1 red light off green light off check the voltage between terminal A4 and B2 60V if the voltage is normal controller is fault if not check the wire connection 2 green light on red light off check the DC contactor coil voltage 12...

Page 32: ...t on red light twinkle Flicker mode 0 25s on 0 25s off 0 25s on 0 25s off 0 25s on 2s off loop check the plug which for motor hall sensor 4 green light on red light twinkle Flicker mode 0 25s on 1s off 0 25s on 1s off 0 25s on 2s off loop check the motor temperature 5 green light on red light twinkle Flicker mode 0 25s on 0 25weixinsoff loop Controller system fault replace a new one ...

Page 33: ...3 3 5 LIGHTING SYSTEM FOR USA MODEL TROUBLESHOOTING Procedure Check 1 Fuse Main 4 Lights switch 2 Battery 5 Distance light switch 3 Main switch 6 Wiring connection entire lighting system ...

Page 34: ...Y Check the battery condition Clean battery terminals 3 Main switch NO CONTINUITY CHECK SWITCHES Replace the main switch 4 Light switch NO CONTINUITY CHECK SWITCHES Replace the light switch 5 Distance light switch CHECK SWITCHES Replace the H L demo light switch ...

Page 35: ...t 2 Voltage Connect the pocket tester DC20V to the headlight A When the distance switch is on low beam B When the distance switch is on high beam Headlight Tester lead White or Blue lead Tester negative lead Green lead high beam Turn on the main switch Turn on the light switch Turn the distance switch to low beam or high beam Check for voltage 12V on the lead at bulb socket connectors OUT OF SPECI...

Page 36: ...t CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Brown terminal Tester lead Green terminal Turn on the main switch Turn the lights switch to pilot position Check the voltage 12V on the bulb OUT OF SPECIFICATION The wiring circuit from main switch to bulb connecto is faulty This circuit is not faulty ...

Page 37: ... Reverse indication 14 Low voltage alarm LCD 15 Electric quantity display 8 Parking indicator 16 Motor tachometer 17 Function button INSTRUMENT OF THE FUNCTION BUTTON 1 When the main switch open the meter is on Self checking status press the button for 5s can make km mile exchange 2 In the meter working status press the button can choose the short mileage and total mileage 3 In the display of shor...

Page 38: ...3 7 WIRING DIAGR ...

Page 39: ...some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 4 1 FRONT A ARM REPLACEMENT 4 2 REAR A ARM REPLACEMENT 4 3 REAR STABILIZER BAR REMOVAL INSTALLATION 4 4 FRONT STRUT REPLACEMENT 4 5 FRONT STRUT BALL JOINT REPLACEMENT 4 6 BOX REMOVAL INSTALLATION 4 7 STEERING ASSEMBLY REMOVAL INSTALLATION ...

Page 40: ... NOTE Tighten the nuts only finger tighten at this time They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 7 Attach A arm to strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are not aligned tighten nut slightl...

Page 41: ...3 4 2 REAR A ARM REPLACEMENT 1 Elevate and safely support vehicle with weight removed from the rear wheel s 2 Remove the wheel nuts and wheel NOTE To ease the removal of the spindle bolt remove the hub cap and loosen the spindle bolts before removing the wheel ...

Page 42: ...ine or damage may occur 5 Loosen two bolts that secure the rear knuckle to the A arm Remove the rear knuckle assembly by sliding it off of the axle 6 Remove the bolt that secures the shock and coil to the lower A arm 7 Loosen the bolt that secure the A arm to frame by alternating each about 1 3 of the way until A arm can be removed Perform this procedure on the upper A arm 8 Examine the A arm bush...

Page 43: ...cle frame Apply Loctite 242 to screw threads of the A arm bolts and torque bolts to 44 ft lbs 60 Nm DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 13 Attach A arm to rear knuckle Tighten upper and lower bolts to 44 ft lbs 60 Nm 14 Install the shock and tighten shock bolt to 32 ft lbs 44 Nm 15 Install the stabilizer and tighten nut to 40 ft lbs ...

Page 44: ...ch side 3 Remove the stabilizer bar nut from the lower A arm each side 4 Remove the two bolts that secure the stabilizer bar to the main frame each side 5 Remove the stabilizer from the frame 6 Inspect the stabilizer bar Inspect the bushings and replace if needed 7 Inspect the stabilizer joint and replace if needed 8 Reverse the procedure for installation Torque the stabilizer bolts to 23 ft lbs 3...

Page 45: ...LACEMENT 1 Hold strut rod with wrench and remove top nut 2 Compress spring 3 Remove upper strut pivot assembly 4 Remove coil spring and collapse strut body 5 Remove two pinch bolts from strut body 6 Remove strut body 7 Install front shock cartridge until bottomed in strut casting ...

Page 46: ... Remove cotter pin from ball joint 5 Remove castle nut and separate A arm from ball joint stud 6 Remove screws and ball joint mounting bracket 7 Using ball joint cup removal installation toolkit remove ball joint cup from strut housing Refer to photos at right Install puller guide 1 Thread bolt 2 with nut 3 onto bal joint stud as shown Hold bolt 2 and turn nut 3 clockwise until ball joint is remov...

Page 47: ...rest of the removal process The box is not as stable with the hinge pin removed 7 With the hinge pins removed remove the box from the frame Two people may be needed to remove the bed from the frame CAUTION Use caution when removing the box It is recommended to have two people to carefully remove the box from the frame Box Installation 1 Place the box onto the frame Align the hinges of the box with...

Page 48: ...over and the steering wheel 2 With the steering wheel holder nut removed remove the steering wheel holder 3 Remove the steering column bolts 4 Remove the upper of the steering column 5 Remove the cotter pins and the tie rod end bolts both sides 6 With the cover bolts removed remove the steering assy and the lower of the steering column 7 Reverse the procedure for installation ...

Page 49: ...CHAPTER 4 CHASSIS SERVICE MANUAL CHAPTER 4 CHASSIS PAGE 4 11 NOTES ...

Page 50: ...CHAPTER 4 CHASSIS SERVICE MANUAL CHAPTER 4 CHASSIS PAGE 4 12 ...

Page 51: ...s refer to Parts Manual of each CUV model for spare parts information and service 5 1 WHEEL HUB AND SPINDLE TORQUE TABLE 5 2 FRONT HUB EXPLODED VIEW 5 3 FRONT HUB REMOVAL INSPECTION 5 4 FRONT HUB INSTALLATION 5 5 FRONT HUB BEARING REPLACEMENT 5 6 REAR HUB EXPLODED VIEW 5 7 REAR HUB AND KNUCKLE REMOVAL INSPECTION 5 8 REAR HUB AND KNUCKLE INSTALLATION 5 9 REAR DRIVE SHAFT REMOVAL 5 10 REAR DRIVE SHA...

Page 52: ...cking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal 5 2 FRONT HUB EXPLODED VIEW 5 3 FRONT HUB REMOVAL INSPECTION 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before begin...

Page 53: ...Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion or roughness is evident 5 4 FRONT HUB INSTALLATION 1 Inspect the hubstrut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Install spindle through the backside of the hubstrut Install the hub onto the spindle 4 Install spindle nut and tighten to 101 ft lbs 137 ...

Page 54: ...CEMENT 1 Remove outer snap ring 2 Form the back side tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by fe...

Page 55: ...g the tire Wheel firmly and checking for movement Grasp the top and bottom of the tire The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel 4 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 5 Remove hub cap cotter pin front spindle nut and...

Page 56: ...Install the wheel and wheel nuts Torque wheel nuts to 59 ft lbs 66 Nm 7 Lower the vehicle Torque the spindle retaining nut to 101 ft lbs 137 Nm Install a new cotter key and the hub cap 8 Install brake caliper using new bolts Apply Loctite 242 to threads Tighten bolts to 18 ft lbs 24 Nm 5 9 REAR DRIVE SHAFT REMOVAL 1 Repeat of the steps in the REAR HUB AND KNUCKLE REMOVAL section 2 Slide the rear d...

Page 57: ...riveshaft into the rear gearcase Be sure the circlip is securely fit into the rear gearcase Use a rubber mallet to tap on the outboard end of the driveshaft if necessary 3 Slide the rear drive axle into the knuckle 4 Lift knuckle into place and install bolt to upper and lower control arm Torque bolt to 44 ft lbs 60 Nm 5 Install the washer and the spindle retainer nut 6 Install the wheel and wheel ...

Page 58: ...APTER 5 FINAL DRIVE 5 8 7 Lower the vehicle Torque the spindle retaining nut to 101 ft lbs 137 Nm Install a new cotter key and the hub cap 8 Install brake caliper using new bolts Apply Loctite 242 to threads Tighten bolts to 18 ft lbs 24 Nm ...

Page 59: ...CHAPTER 5 FINAL DRIVE SERVICE MANUAL CHAPTER 5 FINAL DRIVE 5 9 NOTES ...

Page 60: ...on 6 1 SPECIFICATIONS 6 2 TORQUE 6 3 BRAKE SYSTEM SERVICE NOTES 6 4 BURNISHING PROCEDURE 6 5 BRAKE BLEEDING FLUID CHANGE 6 6 PARKING BRAKE AND BRAKE LINE INSPECTION 6 7 PARKING BRAKE ADJUSTMENT 6 8 PARKING BRAKE REAR CALIPER REMOVAL INSTALL 6 9 FRONT PAD INSPECTION REMOVAL REPLACEMENT 6 10 FRONT DISC INSPECTION REMOVAL REPLACEMENT 6 11 FRONT CALIPER REMOVAL INSPECTION INSTALLATION 6 12 REAR BRAKE ...

Page 61: ...67 4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051mm Brake Disc Run out 0 005 0 127mm 6 2 TORQUE Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bolts 18 0 25 Rear Caliper Mounting Bolts 18 0 25 Front Brake Disc 18 0 25 Rear Brake Disc 18 0 25 6 3 BRAKE SYSTEM SERVICE NOTES It is strongly recommended always change the caliper and or the master cylinder...

Page 62: ...the brake pads use the following procedure 1 Choose an area large enough to safely accelerate the CUV to 50 km h 30 mph and to brake to a stop 2 Using hi gear accelerate to 50 km h 30 mph then compress brake lever pedal to decelerate to 0 8km h 5 mph 3 Repeat procedure on each brake system 20 times until brake pads are burnished 4 Adjust the mechanical parking brake if necessary 5 Verify that the ...

Page 63: ... the hose fits tightly on the fitting 6 Slowly pump foot pedal until pressure builds and holds 7 Hold brake pedal on to maintain pedal pressure and open bleeder screw Close bleeder screw and release foot pedal NOTE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder 8 Repeat procedure until clean fluid appears in bleeder hose and al air has been purged ...

Page 64: ...ir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 1 3cm 14 Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion Replace hose if w ear or abrasion is found 6 6 PARKING BRAKE AND BRAKE LINE INSPECTION ...

Page 65: ... 1 Push the parking brake up with your hand 2 After 2 to 4 clicks of lever travel the vehicle should not roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper Parking Brake Adjustment 1 Place the vehicle in neutral on a flat level surface 2 Carefully lift the rear of the vehicle off the g...

Page 66: ... Damage to the pads may cause the pads to function improperly 1 Loosen the two brake caliper bolts in equal increments Remove the bolts from the bracket and lift park brake assembly out 2 Measure the thickness of the caliper parking brake pads Replace pads if worn beyond the service limit Service Limit 0 3 64 1 mm Park Brake Caliper Installation 1 Install the park brake assembly into place Tighten...

Page 67: ...may occur if machine tips or falls 2 Remove the front wheel 3 Remove the two caliper bolts and caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as r...

Page 68: ...til pressure has been built up Maintain at least 1 2 13 mm of brake fluid in the reservoir to prevent air from entering the brake system 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counter clockwise 6 Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside...

Page 69: ...unout exceeds specifications Brake Disc Runout Service Limit 0 005 0 127 mm REMOVAL REPLACEMENT 1 Removal caliper and hub Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install new disc on hub and tighten to specified CAUTION Always use new brake disc mounting bolts Front Brake Dis...

Page 70: ...Banjo Bolt Torque 15 ft lbs 21 Nm NOTE If new brake pads are installed it is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Repeat procedure 10 times 6 12 REAR BRAKE PAD REMOVAL INSPECTION INSTALLATION NOTE The brake pads should...

Page 71: ... Replace pads if worn beyond the service limit Service Limit 0 3 64 1 mm INSTALLATION 1 Install new pads in caliper body 2 Install caliper and torque mounting bolts Brake Caliper Torque 18 ft lbs 25 Nm 3 Turn adjuster screw back in finger tight using a hex wrench 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 13 mm of brake fluid in the reservoir to prevent ai...

Page 72: ...gh outer pad pad spacer and inner pad 7 Install caliper and torque mounting bolts to 18 ft lbs 25 Nm 8 Install brake hose and tighten to specified torque Banjo Bolt Torque 15 ft lbs 21 Nm 9 Bleed 10 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when lever is released If the brake drags recheck assem...

Page 73: ...nce between measurements 3 Mount dial indicator as shown to measure disc runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 0 005 0 127 mm REMOVAL REPLACEMENT 1 Removal wheel hub and caliper 2 Remove bolts and disc from the flange 3 Clean mating surface of disc and hub 4 Install new disc on flange Tighten to specified Rear Brake Disc Moun...

Page 74: ...CHAPTER 6 BRAKES SERVICE MANUAL CHAPTER 6 BRAKES PAGE 7 15 NOTES ...

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