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CHAPTER 6 BRAKES
INSTALLATION
1. Lubricate mounting bracket pins with a light film
of All Season Grease, and install rubber dust
boots.
2. Compress mounting bracket and make sure dust
boots are fully seated. Install pads with friction
material facing each other. Be sure pads and disc
are free of dirt or grease.
3. Install caliper on hub strut, and torque mounting
bolts.
Front Caliper Mounting Bolts
Torque 18 ft. lbs. (25 Nm )
4. Slowly pump the brake lever until pressure has
been built up. Maintain at least 1/2 "(13 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
5. Install the adjuster screw and turn clockwise until
stationary pad contacts disc, then back off 1/2
turn (counter clockwise).
6. Be sure fluid level in reservoir is up to MAX line
inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7. Install wheels and torque wheel nuts.
8. It is recommended that a burnishing procedure
be performed after installation of new brake pads
to extend service life and reduce noise. Start
machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Repeat
procedure 10 times.
6.10 FRONT DISC INSPECTION /
INSPECTION
1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer and a dial indicator. Replace disc if
worn beyond service limit.
Brake Disc Thickness
New 0.150-0.164" (3.810 - 4.166 mm)
Service Limit 0.140"（3.556 mm）
T-Boss 550 SERVICE MANUAL20.0
REMOVAL / REPLACEMENT
CHAPTER 7
BRAKES
PAGE. 7-
9
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