Brake Linkage; Brake Pedal Bumper Adjustment; Master Cylinder; Brake Fluid - Ezgo WorkHorse ST 480 Technician's Repair And Service Manual

BRAKES
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Disconnect primary brake line where it connects to flexi-
ble brake hose. Provide a catch pan for the released
brake fluid. Remove clip anchoring flexible brake hose to
subframe.
Disconnect clevis yoke from upper arm of bellcrank in
front of master cylinder. Disconnect linkage rod clevis
yoke from lower arm of bellcrank to allow bellcrank to
swing out of the way. Pull clevis yoke and push rod out of
master cylinder and remove boot.
Remove three lock nuts, lock washers and bolts and
remove master cylinder from vehicle.
Remove flexible brake hose from branch tee.
Remove brake light switch from branch tee.
Remove plug from branch tee.
Do not reuse existing branch tee on new master cylinder.
Install new branch tee on new master cylinder using tef-
lon tape and tighten so that one of the three threaded
holes points straight down toward the ground at 70 - 80
in. lbs. (8 - 9 Nm) torque.
Install plug into branch tee using teflon tape and tighten
to 70 - 80 in. lbs. (8 - 9 Nm) torque.
Connect flexible brake hose to branch tee using teflon
tape and tighten to 190 - 200 in. lbs. (21.5 - 22.6 Nm)
torque. Anchor other end to subframe with clip. Connect
primary brake line to flexible brake hose and tighten fit-
ting to 70 - 80 in. lbs. (8 - 9 Nm) torque.
Install brake light switch into branch tee using teflon tape
and tighten to 70 - 80 in. lbs. (8 - 9 Nm) torque.
Mount master cylinder to frame bracket using new lock
nuts. Do not reuse original lock nuts. Tighten lock nuts to
28 - 32 in. lbs. (3 - 4 Nm) torque.
Insert push rod through rubber boot and washer into
master cylinder (make sure rod is through washer inside
boot). Snap rubber boot back onto master cylinder.
Install both clevis yokes back onto bellcrank using clevis
pins and new cotter pins.
!
brake fluid, never reuse any excess fluid or
return to the original container. Dispose of
brake fluid properly.
Fill reservoir with DOT 3 brake fluid and bleed brake sys-
tem. See 'BLEEDING AND FLUSHING' on page D-9.
After bleeding brake system, check for leaks along all
lines and at master cylinder.
Page D-4
T o p r e v e n t b r a k e
!
f a i l u r e r e s u l t i n g
from contaminated
Repair and Service Manual
Connect the negative (-) battery cables.

BRAKE LINKAGE

The brake pedal linkage is set at the factory. However, if
the master cylinder should have to be replaced, the link-
age may require adjustment.
The master cylinder is located under the driver seat and
is connected to the brake pedal by clevis yokes,
threaded rods and a bellcrank.
Adjustment
Tool List
Wrench, 1/2" ................................................................1
Pliers............................................................................1
Crowfoot wrench, 1/2", 3/8" drive ................................1

Torque wrench, in. lbs., 3/8" drive................................1

The master cylinder has built in free travel.
Distance between rubber bumper and bumper mounting
plate should be 7/8" - 1" and the brake pedal arm should
be approximately parallel to brake pivot bracket (Ref Fig.
3 on page D-4). If adjustment is needed, loosen lock nut
and thread bumper in or out of mounting bracket as
required and tighten lock nut to 13 ft. lbs. (18 Nm) torque.
Lock
Nut
Brake Pedal Brake
Arm Pivot
Bracket
Fig. 3 Brake Pedal Bumper Adjustment
Remove cotter and clevis pins attaching linkage rod to
brake pedal arm but maintain alignment of holes (Ref
Fig. 4 on page D-5). At this position, the push rod on
opposite arm of bellcrank should be against piston in
master cylinder but should not be applying any force. If
push rod is not against piston or is applying force, loosen
jam nut at free end of linkage rod and thread clevis yoke
Qty. Required
Bumper
Mounting
Plate
7/8 - 1"
Rubber
Bumper