12
Master
Cylinder
• Test the rear brake lever free play. Apply light
pressure to the left brake lever until you feel the
brake engage. There should be very little free play
between the “at rest” position of the brake lever
and the applied position of the brake lever.
Acceptable free play is between 3/8" and 3/4" (Fig.
1). Keep the brake cable adjusted to maintain
acceptable free play.
• Use a wrench to adjust the brake adjustment nut
on the rear wheel (Fig. 2). Tighten as necessary
until the correct freeplay is established.
NOTE:
If you tighten the nut too much, the rear wheel will “drag”, even if the brake is not applied.
• Make sure the brake adjustment nut is in the correct position after adjusting. The curved side of the nut must rest snugly
against the pivot pin (Fig 2a). Check brake operation.
Routine Care and Maintenance,
continued
CHECK REAR DRUM BRAKE SHOE WEAR
• As the drum brake shoe linings wear, freeplay in the brake lever will increase. Each
time the brake adjustment nut is tightened to decrease freeplay in the brake lever,
the brake wear indicator will move to a position closer to the minus (–) sign (Fig. 3).
•
The indicator should never reach the minus sign.
Brake shoes should be
inspected and replaced by a QUALIFIED MECHANIC before the indicator reaches
the minus sign. The brake shoe must be replaced before the lining reaches the
minimum allowed thickness of 0.06" (1.5 mm). The brake drum must never
measure larger than 3.892" (99.0 mm) in diameter.
CHECK FRONT DISC BRAKE FLUID LEVEL
• Locate the front brake master cylinder under the housing near the right handlebar
(Fig. 4). If the fluid level in the window is at or below the low-level mark, take the
scooter to your dealer for service.
CHECK FRONT DISC BRAKE PAD WEAR
• As the disc brake pads wear, the depth of the notches in the disc brake pads will
decrease (Fig. 5).
NOTE:
The disc rotor has been removed for clarity in Fig. 5.
The disc rotor is shown in place in Fig. 5a.
•
Never allow the notches to wear away completely.
Brake pads should be
inspected and replaced by a QUALIFIED MECHANIC while the notches are still
visible. The brake pads must be replaced before the pads reach the minimum
allowed thickness of 0.072" (1.85 mm). The minimum allowed thickness for the
disc rotor is 0.118" (3.0 mm).
REAR DRUM BRAKE ADJUSTMENT
5
3
FRONT DISC BRAKE
FRONT DISC BRAKE
REAR DRUM BRAKE
REAR DRUM BRAKE
WARNING
• Never allow the front disc brake notches to wear away completely.
• Never allow the rear drum brake pad indicator to reach the minus sign.
• Even if working properly, the brakes should be inspected by your dealer at
the intervals listed in the Professional Maintenance Schedule on page 17.
Time to replace
brake shoes
Time to replace
brake shoes
Time to replace
brake shoe
Time to replace
brake shoe
4
5a
2
Pivot Pin
Pivot Pin
2a
1
Between
3/8" and 3/4"
Brake
Adjustment
Nut
Brake
Adjustment
Nut
