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Unit 20, Ravenhurst Court, Birchwood, Warrington, WA3 6PN
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Chain Adjustment
Lift the rear of the buggy off the ground on suitable blocks;
On both sides slacken the 2 x 14mm wheel shaft nuts;
Starting on the brake side, remove the 2 x 8mm bolts attaching the
caliper to its mounting bracket. Lift the brake caliper out of the way
(handbrake should be off, and NB brake should not be operated while
caliper is not on the disc);
Slacken the 2 x 10mm locknuts from the bolts attaching the caliper
bracket to the chassis, and then slacken the 2 x 8mm bolts (the bracket
will remain attached to the buggy as the rear wheel shaft passes through
it);
On both sides slacken the 2 x 13mm locknuts from the bolts situated in
front of the wheel shaft, and then slacken the 2 x 10mm bolts;
Slacken the 2 x 10mm chain adjuster nuts located one each side at the
rear of the buggy;
Gradually tighten the two chain adjuster nuts. The aim is to have
between 10mm to 15mm free play on the longest travel of the chain, and
maintain the wheel in a position so that the chain is running in a straight
line between the rear sprocket and the motor sprocket;
Once you are happy with the tension, re-tighten all the bolts and lock
nuts, and re-install the brake caliper;
Replace the body panel bolts.
Brake caliper replacement
Disconnect the hydraulic pipe banjo union from the brake caliper using a
10mm spanner;
Take care that any brake fluid which comes out of the pipe or caliper
does not touch any painted surfaces – it is a highly effective paint
stripper;
Remove the brake caliper from its bracket by undoing 2 x 8mm bolts;
Install the new caliper complete with brake pads, and tighten into
position using 2 x 8mm bolts;
Re-connect the hydraulic banjo union;
Inspect the brake fluid level in the reservoir on the handlebars and
replenish as necessary using DOT 2 or DOT3 formulation fluid only;
Slacken the bleed nipple on the brake caliper, and operate the brake
lever. This should expel air from the caliper;
Tighten the bleed nipple whilst continuing to hold the lever (it may be
useful to have an assistant when you do this);
Repeat as necessary until all air is expelled, whilst continuing to maintain
the fluid level within the reservoir.
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