E-Bike 36V Service Manual download pdf (Page 28)

CAUTION

Do not set the caliper-arm spring tension too

high.

c. If necessary, balance the caliper arms by

turning the spring-tension adjuster (B,

Figure 4) on either arm.

11. Adjust the brake lever free play as

described in this chapter.

BRAKE LEVER

Removal

1. Remove the handlebar grip from the handle-

bar.

2. If removing the left brake lever, perform the

following:

a. Loosen the mounting screw, and remove

the mirror from the left-end of the han-

dlebar (Figure 5).

b. Loosen the set screw on the shifter, and

remove the shifter from the handlebar.

Lay the shifter over the handlebar so it is

out of the way.

FIG. 5

FIG.4

Chapter Five

5-2

A

B

7. Remove the brake cable. If you are replac-

ing the rear brake cable, remove the left side

cover, and remove the cable from the rear inlet

on the side cover.

Installation

1. At the brake lever, align the slots in the

brake lever, adjusting barrel, and the adjuster

locknut.

2. Pull the brake lever to the handlebar, and fit

the inner cable barrel into the cable anchor in

the brake lever (Figure 3).

3. Slide the inner cable through the slots in

the brake lever, adjusting barrel, and the

adjuster locknut (Figure 2).

4. Turn the adjusting barrel three full turns out

from its fully-in position. Turn the adjusting bar-

rel and locknut so their slots do not align with

the slot in the brake lever.

5. If necessary, align the brake pads as

described in this chapter.

6. Route the cable to the caliper. If you are

replacing a rear brake cable, route the cable

through the rear cable inlet in the left side

cover.

7. Fit the cable-guide tube and rubber boot

onto the inner wire.

8. Squeeze the caliper arms together, and

connect the cable guide to the bracket (A,

Figure 1) on the left caliper arm.

9. Secure the inner wire in the brake-caliper

pinch mechanism by performing the following:

a. Feed the brake cable inner wire through

the slot in the pinch mechanism.

b. Use the fourth-hand cable stretcher

(Park Tool BT-2) to pull the inner wire

until the combined clearance between

each brake pad and the rim equals

2 mm (0.08 in.).

c.Tighten the pinch bolt (B, Figure 1) to the

specification in Table 4.

d. Crimp a new end cap onto the end of the

inner wire.

10. Squeeze and release the brake lever sev-

eral times, and check the caliper arm balance.

a. The brake pads should contact the rim at

the same time when the brakes are

applied.

b. The gap between each pad and the rim

should equal 1 mm (0.04 in.) when the

brake lever is released.

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