Maintenance And Repairs; Parts Replacement Vs. Repair; Adjusting Brake Pedal Free Travel - E-Z-GO MPT 800 Technician's Repair And Service Manual

BRAKES - REAR MECHANICAL
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

MAINTENANCE AND REPAIRS

Tool List
Hydraulic floor jack ...................................................... 1
Scale ........................................................................... 1
Jack stands ................................................................. 4
Wheel chocks .............................................................. 4
Socket, 1/2", 1/2" drive ................................................ 1
Socket, 3/4", 1/2" drive ................................................ 1
Socket, 11/16", 1/2" drive ............................................ 1
Socket, 15/16", 1/2" drive ............................................ 1
Socket, 1 1/8", 1/2" drive ............................................. 1
Socket, 1/4", 3/8" drive ................................................ 1
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Extension, 6", 1/2" drive .............................................. 1
Ratchet, 1/2" drive ....................................................... 1
Open end wrench, 1/4"................................................ 1
Open end wrench, 1/2"................................................ 1
Open end wrench, 5/8"................................................ 1
Straight blade screwdriver ........................................... 1
Straight blade screwdriver, narrow .............................. 1
Pliers ........................................................................... 1
Vernier/Dial calipers .................................................... 1
Plastic tipped hammer................................................. 1
Puller (P/N 15947-G1)................................................. 1
Pry bar......................................................................... 1
Dust mask ................................................................... 1
Emery cloth ................................................................. 1

Parts Replacement vs. Repair

Some maintenance or repair tasks can take considerable
labor to do correctly. Assessment of the condition of worn
components is critical to the operation of the brake sys-
tem. In some cases, component replacement may be
more cost effective than the removal, cleaning, inspec-
tion and reassembly of the component(s).

Adjusting Brake Pedal Free Travel

Brake pedal free travel MUST be
checked and adjusted any time that the
brake system is serviced or when parts are replaced.
Brake pedal free travel is the distance the pedal travels
from rest to the point at which the brake cables start to
move the brake levers. This should not be confused with
the light resistance that is felt as the brake pedal is
Page K-14
depressed enough to remove slack from the compensa-
tor and cables. Correct adjustment of free travel is
Qty. Required
essential to proper brake function. Too much pedal free
travel will limit braking capability. Too little pedal free
travel may cause the brakes to drag (not fully released).
Either condition can prevent the brakes from adjusting
properly.
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components. The brake system may not be effective
for the first few applications of the brake pedal.
Pre-adjust service brake pedal free travel to the correct
setting by loosening the jam nut and adjusting the spher-
ical nut (Ref Fig. 18 on page K-14). Tighten the jam nut to
10 - 11 ft. lbs. (14 - 15 Nm).
The correct brake pedal free travel should be set to 7/8" -
1 1/8" (2.2 - 2.9 cm).
Press the brake pedal aggressively 4 - 6 times to estab-
lish known free travel.
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of all personnel.
In a safe location free from people and vehicles, drive the
vehicle at reduced speed and apply the brakes aggres-
sively. As the brakes adjust and stop the vehicle effec-
tively, start driving at maximum speed and brake
aggressively 10 times.
Repair and Service Manual
This procedure is intend-
!
ed to adjust the brakes
and seat brake system
7/8" - 1 1/8" (2.2 - 2.9 cm)
Spherical Nut
Fig. 18 Free Travel Adjustment
All brake tests must be
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done in a safe location
with regard for the safety
Jam Nut