3. Squeeze the caliper arms together, and dis-
connect the cable guide from the bracket on
the left caliper arm (A, Figure 1).
4. Loosen the adjuster locknut at the brake
lever.
5. Turn the adjusting barrel and the adjuster
locknut until their slots align with the slot in the
brake lever body.
6. Pull the inner cable from the adjusting bar-
rel, and slide the inner cable through the slots
in the brake lever, adjusting barrel, and
adjuster locknut (Figure 2).
7. Disconnect the cable end from the cable
anchor in the brake lever (Figure 3).
8. Loosen the brake-lever clamp bolt (Figure
6), and slide the brake lever body from the han-
dlebar.
Installation
1. Fit a new brake-lever body onto the handle-
bar, and slide the brake-lever body against the
control housing.
2. Turn the adjusting barrel and the adjuster
locknut until their slots align with the slot in the
brake lever body.
3. Connect the end of the brake-cable inner
wire to cable anchor in the brake lever (Figure
3).
4. Slide the inner cable through the slots in the
brake lever, adjusting barrel and adjuster lock-
nut (Figure 2). Fit the cable into adjusting bar-
rel.
5. Turn the adjusting barrel and adjuster lock-
nut so their slots do not align with the slot in the
brake lever.
6. Squeeze the caliper arms together, and fit
the cable guide into the bracket on the left
caliper arm (A, Figure 1). Be sure the guide
end is completely seated in the bracket.
7A. When installing the right brake lever, install
the handlebar grip so it is flush with the han-
dlebar end.
7B. When installing the left brake lever, install
the shifter onto the handlebar as described in
Chapter Six.
8. Set the brake lever to a 25~35° angle by per-
forming the following:
a. Set the E-Bike
®
in an upright position on
a level surface.
b. Slide the brake-lever body against the
shifter (left brake lever) or against the
handlebar grip (right brake lever).
c. Rotate the brake lever so it forms a
25~35° angle with a line that parallels
the floor (Figure 7). Be sure the brake
lever body does not interfere with the
movement of the throttle lever.
d. Tighten the brake lever clamp bolt to the
torque specification in Table 4.
9. Adjust the brake lever free play as
described in this chapter.
BRAKE LEVER FREE PLAY ADJUSTMENT
1. Pull the brake lever to simulate a panic
stop, and then release the brake lever. Repeat
this at least ten times. This assures that all
components are properly installed and seated.
2. Pull the brake lever until the brake pads just
touch the rim.
3. Measure the clearance between the brake
lever and the handlebar grip. This distance
should be 25 mm (0.98 in.).
4. If the brake lever clearance is not within
specification, adjust the brake lever free play
by performing the following:
a. Loosen the locknut at the adjusting bar-
rel on the brake lever.
b. Turn the adjusting barrel as necessary to
adjust clearance to within specification.
(Turning the adjuster out tightens the
FIG.6
BRAKES
5-3
FIG.7
25 - 35˚
(49 pages)
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