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ADJUSTING THE BRAKE-?
Small incremental brake adiustment
Free play at the handlebar lever i s effected by turning the knurled end on the
cable adjustor. This will allow the lever to be set at the notriinal to
%
inch of
free lever movertierit.
Basic brake adiustinq:
Screw in the knurled cable adjuslor at the brake lever so tlie cable i s in it's
nlost slack starting position.. A t the caliper, loosen the nut,
No.
and tighten
the atljustable bolt=,
so the wlteel cannot turn. Back off bolt
No.
about %
to
X
of a turn and fix it with l o c k nut
N u .
Do not use the cable retainer No.
5
for aclil~stinc~ the brakes!
Fig. 4
FRONT BRAKE PADS REPLACEMENT
-
F s . 1
First screw
i t 1
the knurled cable adiustor at the riaht brake lever (122.002.001 on-
the handlebars to the starling
(slackened cabled).
i o o s e n the 'nut
(920.001.01) and turrr the adj~cstable bolt (512.015.00) i n the way that b y
pressing the front brake lever, the lever (312.017.00) will be over the bolt head
M5 (312.018.00), which protects bt-ake pads and spring of pads (312.020.00).
Unbolt tliis bolt and replace the old brake pac!s wilt) n e v ~ ones. When ~ n o u n t i ~ i g
the brake pads place the brake spriny against both pads, so they are pressed
into the front direction. While replaiinq the brake p a d ~ d _ o ~ n o t
loosen bolts M5
~914.001.011 o n tke drivinq pins and do not loosen t1:e cable retainer!
REAR BRAKE
PADS
REPLACEMENT -FIG.
7
First screw in the knurled cable arliustor a1 the left brake lever (122.001.00) on
the handlebars to the starting po;ition
(slackended cable). ~ o o s e n the'nut
,
(920.001.01) ancl turn the adjustable bolt (512.015.00) ali the way out. Unbolt the
nut M10 (920.001.01) of the back axel, push it o u t and disrnantle the rear wheel
frorn the Swingarm. Push out the brakc from driving pins, that will loosen the
brake pads and replace the old ones a t this time. While replacinq the brake
pads do not loosen bolts M5 (914.001.01
)
o n the drivinq pins and do n o t loosen
the cable retainer!
During the niounting follow all these instructions i n the
reverse direction and then perform basic adjusting of the brakes.
REMOVE AND REPLACE THE FRONT WHEEL
-
FIG. 5
Before dismanlling the front wheel i t is necessary to remove the front hrake
pads f r o n ~ the front brake, so i t i s possible to move the brake caliper from the
wheel a n d be able to draw o u t the v ~ h c e l and tire. Remove the front axe1 nu:.
M1 0 (920.011.07
)
Draw o u t the axe1 front the fork and wheel. Remove
the
whee!
b y an e a s y pull downwards frorn the forlts. CAUTION! Two 3mm spacers Wili
fall o u t w h e n the wheel i s being removed! Insert one spacer between the brake
rotor ancl the brake mounting braclcct, ; ~ n d the other spacer belween the wheel
a ~ i d thc rigltt fork(P1N
315.011.00~
when re-assemb1ing.Return the brake pads
w i t h the s p r i n g and tighten u p the axe1 nut. Perform the basic brake adjusting.
Double check your work. T f ~ i s is ilnportantl
..-p
REMOVE AND REPLACE THE REAR WHEEL -FIG. S
Loosen and remove n u t M10 o n the rear axle. Safelv (hold) k e e p the rear wheel
. ,
.
frorn falling o u t while pulling o u t the nxc!. Caut~on, note the iocation
o f
both
spacer tubes ancl onc spacer washer (between caliper lnount plate ancl rotor)
while removing wheel. When refttting the wheel, ntake sure t o slide the brake
rotor into the caliper between the pads. Hold the wheel i n olacc and fit the
wheel spacers i n proper order.
.
Insert one 31ntn spacer between the brake
r o t o r and brake mounting bracket an? than insert the
9.5fiirn
spacer betrveen
the b r a k e and the rear swing arm.Adjust chain tension and tighten axe1 nut.
Tighten the caliper liolcler plate n u t and set and tighten both chain adjustor
plate M6 nuts. At this time check the brake operation. Recheck all vour vg&,
This i s intportnntl
REPLACEMENT OF PINION
-
F =
First distnantle the front chain g ~ r a ? d 2nd chain guard.Loosen the n u t of rear
wheel a x l e and tlie n u t of cllain tightener .remove chain. Insert carefullv a
larger screw drive o r steel r o d into the hole o f clutch drum, Fig.
9, t o avoici
2
turning over the clutch d r u m a t releasing the pinion. Using t h e pinion wrench
P I N 319.050.00, release the n e w pinion to b e carried out b y reverse way.
FIG.
9
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