12
13
ChApTEr 3
BrAkES
WArrANTy NOTE:
brakes fall under “non-electric” component warranty. applicable warranty is 6 months
from date of purchase. any service issue resulting from misuse of bicycle is not covered under this warranty
and user shall be responsible for all charges.
BrAkE LEVEr rEmOVAL/INSTALLATION
removal
1. note the position of the throttle, shifter and display relative to its handlebar grip. If necessary, measure the
gap between the item and its handlebar grip or make a drawing so these components can be reinstalled
with the proper positioning and orientation. also note the orientation of the handlebar within the handlebar
stem.
2. disconnect the electric brake lever connector at the controller box.
3. at the brake lever, loosen the adjuster locknut (a,
Figure 3-1
) and turn the adjuster barrel (b,
Figure 3-1
)
from the brake lever.
4. turn the adjuster barrel and the locknut until their slots align with the slot in the brake lever housing.
5. pull the cable housing from the adjuster barrel (b,
Figure 3-1
), and slide the inner wire (C,
Figure 3-1
)
through the slots in the lever housing, adjuster barrel and locknut.
6. press the brake lever toward the handlebar, and disconnect the inner wire end (a,
Figure 3-2
) from the
anchor (b,
Figure 3-2
) on the brake lever.
7. remove the handlebar from the handlebar end.
Installation
1. Slide the new brake lever onto the end of the handlebar.
2. make sure the slots in the adjuster barrel and the locknut align with the slot in the brake lever housing
(
Figure 3-1
).
FIGUrE 3-1
B
A
C
3. Connect the end of the brake cable inner wire (b,
Figure 3-2
) to the anchor (a,
Figure 3-2
) on the brake
lever.
FIGUrE 2-9
B
A
FIGUrE 2-10
5. remove the handlebar stem and the upper bearing as described in this chap- ter.
6. lower the fork until the fork column clears the head tube, and remove the front fork.
7. visually inspect the seal, bearing cover, spacer and stem cap for any damage (
Figure 2-10
).
8. manually turn the bearing inner race, and confirm that the bearing rotates smoothly.
9. Inspect the lower bearing in the head tube. If either bearing is faulty, replace both bearings as a set.
Installation
1. after installing the headset as previously referred, slide the fork column up into the head tube until the
lower-bearing collar rests against the lower bearing.
2. Install the handlebar stem as described in this chapter.
3. Install the front wheel.
4. Carefully slide the front brake caliper onto the brake disc so the disc does not mar the brake pads. apply
loctite 242 to the threads of caliper mounting bolts (a,
Figure 2-9
), and evenly tighten the bolts. torque
the caliper mounting bolts to the specification in table 5.
5. Install the handlebar as described in this chapter.
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